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Author Topic: KX80 swapped KX60  (Read 3561 times)
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Jr. Member
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Joined: 01.14.16
Posts: 13

« on: November 09, 2017, 07:08:37 PM »

Hey Guys!
I am bringing back a thread for my engine swapped KX60 after almost two years. It sat in my basement on financial hold for so long. I actually started to do something with it. In the past few months I have been slowly restoring the engine and bike itself. So far I have the rear wheel respoked, new tires front and back, new kx65 clutch cable with custom cable holder, new klx110 front brake cable, klx110 front fender, all the rear brake pieces that were missing, a new chain, throttle cable and throttle. I had the motor apart and it is still somewhat apart, but I got a lot done. I put a new shifter shaft and shifter springs, tusk shift lever, water pump rebuild kit, clutch cover gasket, new boyesen power reeds, new mikuni carb, pod filter, new spark plug, and i have a brand new wiseco piston kit for it. Unfortunately the cylinder walls are badly worn, so I am on hold until I feel like throwing around $200 to get it replated by Powerseal USA. Once that is done, the motor should run like new again. I am very excited. In the mean time, I am planning on just running a stock KX60 radiator, so I need to purchase a radiator and tank with the shroud. The frame is a 1985, the last year that it was air cooled, so I do not have the correct tank. The other major issue I have been thinking about is the exhaust. I still have the stock kx80 expansion chamber, but it is huge and would have to be trimmed down. One problem it might pose is that the KX60 exhaust goes over the head and through the frame to the right side of the frame, but the KX80 expansion chamber would kinda be up against your leg on the left side. So I am weighing my options, I am almost thinking that I may just try to fit up a KX60 expansion chamber, but what kind of affect could that have on the powerband? The biggest thing is that I am making progress. I hope to get it done by spring. If anyone has any advice, I would love to hear it.
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Joined: 03.09.13
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« Reply #1 on: November 10, 2017, 12:37:55 AM »

it would run with the kx60 pipe, but you loose the top end power of the kx80 engine. you have to cut and reweld the pipe, that it fits the kx60 frame ...   it would be a lot easier to find an kx60 /65 engine and install the athena 80cc cylinder kit .. 

big 2 stroke bikes are weapons for real men, who don´t fear death or devil. ;O)
´83 kx250, ´87 kx250 (with 360 big bore), 87 kx500, ´93 kx500 sfc

---  www.der-motopunk.de.tl  ---
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Joined: 01.14.16
Posts: 13

« Reply #2 on: November 16, 2017, 12:25:58 PM »

Its not like im looking for the easy way to do it. Im a welder and feel i have the skill to modify an exhaust, but modification is different than having a completely different expansion chamber. I am weighing my options of even getting some software and designing one and tig welding it. I have the stock kx80 exhaust and it is modified , but the kx60 exhaust goes through the frame whereas the 80 is much different. Im already too far into the 80 engine to just scrap it., let alone the fact that the kx80 engine will suit a larger rider much better and actually last.
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