KX Riders
Commercially available service offered by members of KXRiders. => OEM-CYCLE => Topic started by: sandblaster on May 13, 2016, 02:30:02 PM
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I know I know... It's not green and it's not a bike... But still pretty cool...
We received a pair of CR500 engines to rebuild.
One, the customer needs back within a week.
Also, it will not be a total rebuild.... Not ideal but I'm sure we can still put a smile on his face
(http://www.oem-cycle.com/forum/download/file.php?id=4050)
(http://www.oem-cycle.com/forum/download/file.php?id=4051)
(http://www.oem-cycle.com/forum/download/file.php?id=4052)
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So, the first thing we did was get out the Hot water pressure washer and get all the dirt and grease off this engine.
I hate cracking open a engine with dirt and grease on it..
(http://www.oem-cycle.com/forum/download/file.php?id=4054)
Cracked open the stator cover and found a nice little surprise!
Light weight fly wheel... Yes!! and other goodies...
(http://www.oem-cycle.com/forum/download/file.php?id=4055)
(http://www.oem-cycle.com/forum/download/file.php?id=4053)
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Cool head!
(http://www.oem-cycle.com/forum/download/file.php?id=4056)
Ugh! Not so cool..
(http://www.oem-cycle.com/forum/download/file.php?id=4057)
Oh no... A crack...
(http://www.oem-cycle.com/forum/download/file.php?id=4058)
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I see some improvement to be had..
(http://www.oem-cycle.com/forum/download/file.php?id=4059)
Looks good..
(http://www.oem-cycle.com/forum/download/file.php?id=4060)
Not so fast...
(http://www.oem-cycle.com/forum/download/file.php?id=4061)
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(http://www.oem-cycle.com/forum/download/file.php?id=4063)
(http://www.oem-cycle.com/forum/download/file.php?id=4064)
(http://www.oem-cycle.com/forum/download/file.php?id=4062)
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Cases are back from weld...
(http://www.oem-cycle.com/forum/download/file.php?id=4066)
(http://www.oem-cycle.com/forum/download/file.php?id=4067)
(http://www.oem-cycle.com/forum/download/file.php?id=4065)
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I must love lapping cases... I have gone through a entire can of Timesaver..
(http://www.oem-cycle.com/forum/download/file.php?id=4070)
(http://www.oem-cycle.com/forum/download/file.php?id=4069)
(http://www.oem-cycle.com/forum/download/file.php?id=4068)
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(http://www.oem-cycle.com/forum/download/file.php?id=4072)
This is ugly....
(http://www.oem-cycle.com/forum/download/file.php?id=4073)
Polished the ID of the exhaust flange..
(http://www.oem-cycle.com/forum/download/file.php?id=4071)
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Hogging material
(http://www.oem-cycle.com/forum/download/file.php?id=4075)
First clean up on the cases..
(http://www.oem-cycle.com/forum/download/file.php?id=4076)
(http://www.oem-cycle.com/forum/download/file.php?id=4074)
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The clutch basket is hashed and there is not enough time to get another...
(http://www.oem-cycle.com/forum/download/file.php?id=4078)
So, out come the files :-o I know, I know, that's not all that great but it will get him through a few races..
(http://www.oem-cycle.com/forum/download/file.php?id=4079)
Hogging more material... Jason is a porting machine
(http://www.oem-cycle.com/forum/download/file.php?id=4077)
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Worked on the basket a bit more today..
(http://www.oem-cycle.com/forum/download/file.php?id=4080)
I even cleaned up the inner hub a bit..
(http://www.oem-cycle.com/forum/download/file.php?id=4081)
I've been working on the head but I'm going to see if I can get a new one before Thursday..
It's just too beat up..
(http://www.oem-cycle.com/forum/download/file.php?id=4082)
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Getting it ready to slap together
(http://www.oem-cycle.com/forum/download/file.php?id=4083)
(http://www.oem-cycle.com/forum/download/file.php?id=4084)
More progress..
(http://www.oem-cycle.com/forum/download/file.php?id=4090)
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(http://www.oem-cycle.com/forum/download/file.php?id=4089)
(http://www.oem-cycle.com/forum/download/file.php?id=4091)
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Race day
(http://www.oem-cycle.com/forum/download/file.php?id=4098)
(http://www.oem-cycle.com/forum/download/file.php?id=4097)
(http://www.oem-cycle.com/forum/download/file.php?id=4096)
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(http://www.oem-cycle.com/forum/download/file.php?id=4100)
(http://www.oem-cycle.com/forum/download/file.php?id=4101)
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The results?
3 laps in...
(http://www.oem-cycle.com/forum/download/file.php?id=4099)
(http://www.oem-cycle.com/forum/download/file.php?id=4103)
The reason?
Plugged pilot, and floats set too low.
Lesson learned... Next race build, we will have the carb, check the jetting, and break the engine in.
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Yesterday we received a 91mm CR500 Wiseco piston.
I took the cylinder and piston to the machinist and told him the specs I wanted it bored to. I should have it early next week.
We will be getting the Kart this time so we can tune it and break it in over a few days.
I can't wait....
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Ready for it's first heat cycle...
(http://www.oem-cycle.com/forum/download/file.php?id=4184)
https://youtu.be/NyoDQR4CDTY (https://youtu.be/NyoDQR4CDTY)
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I think Jason want's one...
This pic was taken after the fourth heat cycle yesterday evening.
I'm sure my neighbors are just as happy about it as I am :-D
(http://www.oem-cycle.com/forum/download/file.php?id=4186)
I want one as well... But I want mine to be green 8-)
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I'll take one too...but make mine outa Mahogany....seeing's how I'll probably need to be buried in it. :mrgreen:
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Race results.
1st heat placed 1st.
Second heat placed 4th.
Main was in second but spun out. Had to start over from the rear of the pack, ended up placing 3rd but was DQ'd due to a early restart that everyone says was bunk.
Oh well, that's racing.
Overall I'm not dissatisfied with the results especially considering that we have a lingering lean issue.
We think we know the cause but will get it resolved next week.
We do have two weeks before the next race so I'm certain we can get this figured out.
Special thanks goes to Adam Millar for his technical support.
Without Adam's help I'm sure we would have finished at the back of the pack....
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Race results.
1st heat placed 1st.
Second heat placed 4th.
Main was in second but spun out. Had to start over from the rear of the pack, ended up placing 3rd but was DQ'd due to a early restart that everyone says was bunk.
Oh well, that's racing.
Overall I'm not dissatisfied with the results especially considering that we have a lingering lean issue.
We think we know the cause but will get it resolved next week.
We do have two weeks before the next race so I'm certain we can get this figured out.
Special thanks goes to Adam Millar for his technical support.
Without Adam's help I'm sure we would have finished at the back of the pack....
Any vids
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Unfortunately we were too busy trying to figure out why we were having a tuning issue..
We think we have it sorted out but will have to verify next week.
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Right on, want to see that thing rip
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Then I'll probably need to throw a KX500 engine in it :evil:
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Then I'll probably need to throw a KX500 engine in it :evil:
Lmfao no $h!t
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This isn't gonna do at all :x
(http://www.oem-cycle.com/forum/download/file.php?id=4199)
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Building a back up engine..
Bearings removed and degreased.. Ready for glass blasting.
(http://www.oem-cycle.com/forum/download/file.php?id=4200)
Glass blasting done, ready for vapor blasting
(http://www.oem-cycle.com/forum/download/file.php?id=4202)
Tig it up Travis..
(http://www.oem-cycle.com/forum/download/file.php?id=4201)
Waiting for installation...
(http://www.oem-cycle.com/forum/download/file.php?id=4203)
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That is awesome! I used to race karts but was in the 100cc Yamaha and 5 HP class back in the 80's. Fun stuff!
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After we get it back together I'm going to see if I can even get in the thing.
If so..... :evil:
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We were really excited for Friday night.
Jason and I spent a full day tuning...
It is running awesome.
So Casey (The driver) goes out and takes his practice laps.
He is all over the place and goes off the track twice.
The last time he went off the track he caught some air.
When he came into the pits he was really excited.
He raved about the engine and how good it ran.
So, the owner (Chris) was changing the chassis around to dial it in for the track conditions and discovered a big crack in the frame right under the drivers seat.
Done for the night...
That's racing... :cry:
But, there is another race next Friday 8-)
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No one had a welder at the track? Does the engine have to be 500cc or could they do something silly and put a Liger big bore cylinder on it.
As always love your work blaster!
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Thanks buddy.
As far as I know there is no limit to the CC.
In fact we discussed a Liger cylinder last night.
I doubt the owner wants to spring for one but I'm certainly game :-o
Then again, you can only use so much power and I think we are just about there.
I'd really like to build him a KX500 engine so we could compare...
He might consider it..
Oh and nobody had a tig welder out there.