KX Guru Racing KtX500e Kawakaze electric start KX500 & KTM Chassis

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Any time you put together a prototype you can expect to run into some issues...
This is a minor issue that will only effect you if you are using the TSR cases with the Panthera E-Start.

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As you can see there is quite a gap between the cases and the starter housing.
The Panthera starter housing has a lip around the outside edge.
The lip goes most of the way around.
I suspect that it is there for alignment.
The issue is that part of the lip hits on the case.

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So a little material has to removed from the starter housing lip area.

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I've got the starter housing ready to machine... Except I put a piece of tape over the vent area that is not shown in this pic..

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In this pic you can see the area of the Engine cases that is interfering with the starter housing.

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Here is what a stock case looks like in the same area.
As you can see it has much more recess in it then does the TSR cases do.

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After a little milling it fits like a glove..

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[Sandblaster]

If you decide to do this project yourself but you don't have a milling machine, You can use a drill press, hand grinder, porting tool, Dremel, or a hand file Or, you could contact Sebastian before you buy a E-Start and ask him if he would be willing to machine that area off for you..
Here is what I used..

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Prepping a 2 piece clutch cover and comparing to the TSR Billet cases

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Clearly I need to step up my game...

[Markee757]

Wild work!

Where you getting your hardware?

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The engine cases TSR products Australia
The 2 piece clutch cover I made.
The Electric Starter is from Panthera in canada
The titanium fasteners are from all over the world but mostly China, US, and the UK

[Sandblaster]

It's time for some changes...
First step... Get rid of the ridge around the kick lever shaft output area.

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Next thing is to get rid of the splash guard for the filler plug..
Cut number 1.

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Cut number 2

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A little mill/drill work..

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[Sandblaster]

(In your best Arnold Schwarzenegger voice) unprogrammed mimetic polyalloy... liquid metal...

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I have never tried this product... We'll see how it works..

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After prepping the cover I taped the back side to keep the material in place..

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Because it Oregon... and it's cold and raining outside, I used the over to keep the temps up...
After applying the filler I let it sit for about 5 minutes then pulled the tape off...
Then I put it in the oven but left the door wide open to keep from over heating it.
My oven only goes down to 170f and that may be a bit warm

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