Sean Colliers KX500 build

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So the cat's out of the bag... KX Guru Racing is building Sean's next bike.
There is so much to be decided... So much to be looked at... So many people to talk to.... It's simply amazing...
So let's get this rolling.

KX Guru Racing
Oscar Cota Project Manager
Jason Tanner (JT Engine Works) Engine and Chassis build Specialist.
Alex Ward (Crazy Al's Racing) Engine and Chassis build Specialist.
Mike Collier Team Liaison
Sean Collier Test Pilot
David Olsen Research & Development Engineer
Adam Millar (Millar Racing Engines) Technical Advisor
Mike Weir General Manager


As some of you know Sean wanted a better back brake.
For those that question why, it's simple..
Sean rides at a level that few of us will ever see.
His brakes fade about half way through a moto.
Ever try racing with a bad rear brake?
So I put a little thought and R&D into it and finally decided on using a complete KX450F rear brake set up.
Even the rear tire will be from a KX450F.

First things first... I used a KX250F rear brake lever.
It was simple and effective.
But why not use the KX500 lever?
Leverage... The KX250F rear brake lever is about 1/2" longer then the stock KX500 lever.
Here is a stock KX250F rear brake lever and a couple of 12mm ID x 16mm OD x 10mm long Oil Impregnated Bronze bushings

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Here is what you will get after you press the bushings in

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This guy will be removed..



All mounted up and there is plenty of clearance.



You can watch the smooth action here

https://www.youtube.com/watch?v=YBoLtIa ... e=youtu.be

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Here is a pic with the Hammerhead Spring and Clevis kit installed.



Here is a pic with another after market lever mounted and ready to try



We are most likely going to use a Hammerhead lever so this will probably be updatedd..

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Because we are using the KX450F rear wheel with axle, blocks, and adjusters, we will need to machine these slots to 25mm



I will need to make a new hanger on the inside of the swing arm to fit the KX450F rear brake caliper mount.



So this guy has gotta go..

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A friend of mine donated a KX500 swingarm for me to ruin...eeeerrrrrr... modify

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Again, this mount for the KX500 rear brake mount has got to go..

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All gone...

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Tomorrow I will get it sand blasted and start working on the new caliper mount.

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Oh... Something showed up this afternoon

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Let's see what we have to work with...

Dirty carb... Check!

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Dirty head... Check!

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Dirty stock cylinder.... Check!

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