Motorrads Jeff Ward engine build series 2

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Okay... how about some final specs for everyone? I just copy and pasted this from my current list...

I havnt updated it.. So I may update it when I have more time (or add items I have forgotten.)

KX500 Info

Head
Larry Wiechman cut/Compression release
.015 step
4deg squish
.0375 squish clearance
Polished to HIGH finish
.0125" Deck hight


Crank
Crank stuffers
Crank webs trued (cut to be round)
New OEM rod, pin, bearing, washers.
Journals Hardchromed back to spec
Big end 373G
Small end 112G
Piston+parts 501G
Final Balance factor of 60.84%
(could have gone 20G ligher, but wanted to stay at 60%)

Piston
Window Ported,
lightened (Kaw Rider),
OEM pin (5g lighter, cut to fit by Larry Wiechman (could have run Kaw Riders Pin, which is 15Grams lighter YET)
coated by truline (uschrome),
oil holes chamfered,
Extra oil Holes added (Kaw Rider),
skirt trimmed near transfer port.
Polished to HIGH finish

CYL
Ported by me, slag cleaned up, Aux ports opened, exhaust polished, case matched, dividers matched, woopies taken out of transfer tunnles, blasted to nice finish, then sent to coating. New coating done by USchrome.,

KIPS
Bolt from KawRider,
ALL new Kips parts. (except for drums)
reshape kips drum to not block ports at Open.
.020" cut from top of Kips drums to move them up, (DoldGuy gets credit for this idea)
Polished to HIGH FINISH
C3 bearings,
new seals
Shimmed to raise to top of Exhaust port
Actuating arm moved (C-Clip cut)
Older style lever used for leverage increase.


INTAKE
Vforce 3 reeds,
1/8" reed spacer (to fix Vforce 3 problem), Also slight taper cut to aim reeds Up...
Sudco 41MM PWK.
Rubber boot, and intake boot port matched to carb and reed stuffer.

Tranny
New Idler gear (under clutch basekt)
All new C3 bearings
New seals
ALL NEW Circlips (a must when they have been used once)
2 NEW shift forks
New shift fork guides (long metal tubes)
All shift forks, and shift drum polished to HIGH FINISH.
OVERDRIVE 5TH GEAR
Clutch basket Cleaned up... (knotches) looking for a Mitika now...

MISC..
Drain Plug Repair by LARRY Wiechman
NEW C3 bearings throughout,
All new seals
New waterpump shaft
Steel clutch plates,
ALL new Kips parts. (except for drums)
Zip-Ty Lowboy FMF pipe (same power as desert Gnarly)
Lightened flywheel
FULL stainless hardware kit. (ooooh its soooo pretty)
Radiators boiled clean at Buddys radiator shop (just for giggles) wasnt any problem...
.010" Headgasket
New head studs, and Case studs..
Currently .020" base gasket... soon to be changed

[Sandblaster]

Forgot to mention to everyone..

Next time you have some wrist pin clips in your hands.... Put a mic on them... I had 5 sets here.... scary the inconsistancy...

Mine match the groove thickness perfectly... Only took 5 sets to get a good pair. grin

Are we anal yet?

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An Update regarding Balance..
I know many were interested in my findings of the 60%..


It is the smoothest single cyl 2T I have ever ridden.. from just off idle (2500) to the 8250RPM I touched this weekend. (would have done more, but was taking it easy)..

I hate to say it... But it is smoother than my 2002 Counterbalanced 4T KTM...

I brought my 200x this trip (as you can see from pictures).... and getting off the KX.. onto the 200... the 200 felt Buzzy...

Keep in mind my crank webs are machined to be round.... they are pretty much Matched on weight one side to the other, AND are true... VERY VERY TRUE... when I checked them they were within .0005"

[Sandblaster]

kaw rider:
here is the size of the opening. found it in another post.

a stock cab measures about 40 mm at the intake side of its bore ..that is about 1.570 dia the rad valve when cut like this has around a 1.300 hole with a bridge in the center thats already removed from this one.


Motorrad:
1.3" thats hmm 33mm then you add a Bridge to restrict area further..

Not sure that will keep up flow with a 42mm carby.. Thats a 10MM differance, not counting the bridge...

I fully believe in taper bore stuff... But my Carb is already taperbored DOWN to 42mm..



On a Fun note..
evil evil evil Port Timing and Port Duration Changes made today evil evil evil evil

[Sandblaster]

Ran some numbers.. (Im currently standing in a high school boiler room watching guys remove asbestos... doing air monitoring, typing on my phone... so... Rough draft......)

Cross section area of my carb (taper bore 42mm Sudco) is
13.8544CC
Cross section area of the Rad valve (not counting divider, based on Kaw Riders 33mm measurement) is
8.5529CC

Difference of
5.3015cc..

So the Percentage of Cross section area change would be..
38.28386649728606%



Like I said. Im all about taper bore, and increasing intake velocities via running big hole into small hole..

But a 38% restriction variance is a big number...

When I get home Ill pull out my engineer nerd formulas and see what that will do to velocities and total flow at WOT...

[Sandblaster]

All the guys running ported, stroked, big bore, big carb, etc etc motors have the same issue I see...

the rad valve is too small to Breath a modded motor.... A Cork if you will

so they all port them out..

Not saying these pictures are done well or even correctly for that matter... just example..

Before.

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AFTER

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[Sandblaster]

Okay.. interesting Bit of info to share...


I fired an email off to Moto Tassinari, explaining the issues Im having (and the fact you can see daylight through these cages)...

and this is the responce I got.

"David

Is the bike modded? Race gas or alcohol? The reeds may not be stiff enough. Send me your address and I will get you a different set up.

Best Regards
Jeff
Moto Tassinari"




Will Be very interesting to see what I end up with huh

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Friar-Tuck:
Well that's cool,
At least they are willing to work with you.
He may be in for a bit of a shock to see the amount of work in the engine..
Who knows, You may have just gotten them to re-visit their offering for the bike.
I can see it now..
Moto Tassinari in Cooperation with K5 power by MotorRad presents the Moto-Rad V-4 for the KX 500.
A new Reed and Cage Package for the Discriminating KX 500 Owner.... cheesy

Tuck\o/


Motorrad:
Hmm where would I start...
Alum cage, thats been Rubber coated to make the reeds live (like stock), snap in reeds like the V3, ONLY id want it to take stock reeds, so I could mix and match.. (say run half medium reeds, and half stiff reeds from carbon tech). as I dont like dual stage reeds.... An Alum intake like the Radvalve... Only with a proper hole in it for "big carb modded motor guys"... 30degree angle (low mid end vs 45deg high end). and STUFFERS to Get the intake charge back where it belongs... In the cases, not the intake..... (darn window pistons dont help this)

Fun to dream isnt it... rolleyes

Would be funny if they just sent me a Vforce 1 setup..

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2-Stroke Tom:
I'll be following this closely, because so far I am just getting more reassurance to stick with the stock reed and cage setup. The fit of the V-force III is unacceptable to me, and I was always surprised to see so many people endorsing them. I guess in a pure horsepower competition, from what I've read (but never personally tested) the V-force III reeds may be the winner when they are brand new. After they warp from heat and use, will they still offer the same performance?


Motorrad:
I have a brand new set sitting here on my bench. (sent to me by mistake, was supposed to be a set of Vforce 2's)... So before i sent them back... I took the liberty to open them, and inspect..

Yep.. Daylight....

Also water timed it..

Not good... there is no way this thing will seal my Stuffed motor...

Id still like a set of V2's to give a shot.. as they seemed to have a stronger petal tension, and the one I had in my hand oh about a year ago now. seemed to have good petal to cage seal.. Sure screws come out... Just RTV them to the cage, like we used to do to all the metal cages...

[Sandblaster]

Not sure what Vforce is sending me in the mail... Will wait to see what it is before I move forward with this....


But I may have accidentally stumbled onto my New setup... evil grin


I vaguely remembered my 87 having a air guide (stuffer) like the V3 reeds do...

so I went up in the loft today to dig out the reed cage off my 87..

Few things different..

1. it has a stuffer/air director BONUS..
2. its missing one ridge in the middle of the cage. (???strength???).
3. NO reed stops..??Could have been removed sometime in its life??.. Havnt consulted Parts diagrams.. BUT the reed stops off the newer cage bolt on...
4. Its rubber coated, but not like the later cage that RAISED the reeds up with a rubber ridge, its rubber coated FLAT,so this would be less prone to blowback vs the newer cage... So I could get away with a softer reed possibly...


I think Im going to build a HIBREED cage.. consisting of.

1987 reed cage,
1987 reed stuffer
1988-04 reed stops
Carbon Tech "smooth power band" reeds

NOW Stand back and watch all the 1987 reed blocks get bought off ebay rolleyes

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