Crofter985'S KLX650C supermoto build

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Crofter985

That's impressive performance figures, looks a good neat build.
So that's a good pointer as to what to do with the comp ratio, leave it alone, the '93 KLX is 9.5:1 so it's not so much anyway.

You said you were planning a similar project? A turbo thumper?

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Crofter985

Got a picture sent to me last night from my wife, I've been waiting for this delivery. It's a lathe, just a small one but hopefully big enough to hack out some bespoke parts for the KLX build, it will possibly take a moment to get it set up and me set up, it's been +25 years since I operated one of these, when I was at the school.

I've had an idea for the plenum, I'm thinking of cutting the subframe off the bike and making up a monocoque aluminium subframe that doubles as the plenum and also houses the tank for the water/meth injection and the W/M injection pump. I got the W/M kit a couple of weeks ago and I was a bit disappointed on the size of the pump, I should have known, the kit catered for +500hp so it probably figures. The lowest point of the tank has to be above the pump and the W/M jet has to be above the pump. The battery would need to go there somewhere too so.....
If I make an integral rear fender/tank, a plenum(up to 4litres and as near to that as possible) with a recess for the battery and a tray space under the seat to put the CDI and reg/rectifier.
This is absolutely a case of easier said as done, there's a lot of fabrication there but what the hell, what is right up mu street is finding an elegant solution, something that has dual purpose, I don't have a big love of polishing things but it has to look right or it will be a constant irritation till it' is right. I'm not a stranger to changing my mind about stuff so that is only the current version, last week I was building a plenum inside the original subframe but I went off this idea because of the volume I was going to potentially loose making it fit around the subframe rails. There is a few things to go on here yet. Fuel pump, fuel pressure regulator, wideband, just saying all this makes me think of weight. But if I can get it running well and looking the way I want it, I will perhaps have to be content with that.
It will be a couple of weeks before I get some time off again so I've ordered a couple of books on metal turning and I'll swot up on that so I refresh my memory on the lathe and find out about turning stainless, I didn't do any of that before and I would like to make a couple of exhaust parts out of that.
And that's all for now, what do you think.? Am I barking up the wrong tree?

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Crofter985

Got a bit of old bar that was lying around. It wasn't even straight.

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Turned it down to just under 12mm, drilled a 5.5mm hole down the middle.

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Then parted off a bit that looked big enough.

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This is the relief valve, I've taken the retaining circlip off....

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Spacer under the washer and on top of the spring.....

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And circlip back on. Spring preloaded.
Going to tackle the exhaust next so I can get the turbo mounted on the bike.

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yz133rider:

Nice project!!

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Crofter985

Thanks yz133rider.
Right, exhaust.

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Turned the exhaust stub and a flange to press down on the stub out of some bits of stainless.

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Another view of the parts.

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That's it together and on the bike, I've tacked a 1 1/4" 90' elbow on to it and if you look close you can see a red line which I drew on it that is in line with the seams in the side cases. I cut it there next on a chop saw.

At this stage I made up these three alloy spacers, they are to space off the radiator, it was too near the exhaust stub and flange, well it was the rad hose that was the problem. This should sort it, they are 14mm long, I might shorten them yet but ok for now.

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There is the exhaust, or pre turbo exhaust anyway, I got a guy I know to cut a couple of manifold flanges and a couple of turbine exhaust flanges out of 12mm stainless plate on a water jet cutting rig, nice job, even cut the bolt holes.
And there's the turbo mounted. For now.
I've altered a lot of bits so far, some of this might be junked as I go along, I hope not but we will see how we go.

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Crofter985

Another view.

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It sticks out a bit. I'm not too worried about that, I like the idea of the turbo OUT THERE, in yer face. I'm liking it there.

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Nic likes it too, yaay! I might throw the tank on and the rad shroud to see what it looks like. There is a yamaha 250 turbo kit available in America that has turbo in this position and it seemed to work. As you can see I'm going with the turbo as near to the exhaust valve as possible
That's it for just now, think I'll go back to the shed and look at it for a bit, see where I'm going next. There is an adaptor to be made for the oil feed into the turbo, that would be a possibility.

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yz133rider

I was just check in out the yamaha wr250r/x turbo kits. 45-55hp up from 22 lol.

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Crofter985

Plastics on, that works not bad, perhaps minimum mods for the plastics!

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You can see the alloy spacers in this pic. And another view of the exhaust. BTW I'm going to leave the exhaust like that for now, just tacked, might be mods to go yet.
The rad shroud fits good with that spacer behind the radiator so that's a plus.

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Crofter985

Here's a few problems to overcome. Oil line adaptor is too long, fouls on one of the m5 bolts holding on the compressor housing on. And the oil line fouls on the waste gate actuator, same problem though as shortening the oil line adaptor will fix this too.
Also now I've rotated the turbo around so it fits the new application, the holes in the outer edge of the compressor do not line up with the holes in the waste gate actuator. I've just had a thought, it might be able to be turned around? Failing this, I might drill and tap some new holes to line up with the holes in the bracket.

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CR500XR650RNORWAY

Hi! Nice projeckt on my xr650turbo i dont use the waste clock i just runing a dump valve on my plenium,im also runing the oil feed from the oil filter housing no oil cooler i have started to rebuild build the turbo setupp biger plenium 4,2 liters and i did som mod on the seat frame,but im going to keep the turbo location its work very vell the road police here in norway is no fan of turbobikes so my gold here is to hied the turbo as much as posible, on my last trips before rebuild i vas runnin 20% e85 and 80% bf98 that gives me a presure at 8000rpm 1,05 bar/15-16psi crazy funny. What mods in the engine are you gona do?