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Old 09-14-2013, 04:58 AM   #31
Quirky
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This is going to be a great project. Go Fogo.
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Old 09-14-2013, 05:16 AM   #32
Fogo72 OP
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Here are the forks that I bought off fleebay in the States, on a plane as we speak. gunna look sweet.

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Old 09-14-2013, 05:23 AM   #33
KASUYAHO
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Think outside of the square

Quote:
Originally Posted by Fogo72 View Post
STD bore is 100mm
STD stroke is 83mm
New stroke is or will be 89mm
1mm off pistom crown , no biggy, kind of domes in so it will just be a little around the out side.
Piston pin, not sure, have book. will find out.
Same with rod length, can find out,
why , whats your thoughts.
Just playing around looking at different options
Your KLX
Bore 3.937
Stroke 3.27
Longer stroke 3.50
42.7 CI = 699cc
Specs are close to 360ci mopar 4.00 bore 3.58 stroke, 6.123 rod length
Wrist pin dia .9842 in

Chev SB from memory has a .750 wrist pin dia,
350 chev has a 4 inch bore, same as 400 chev, which has different pistons
has it has a different compression height.
Forget what the compression height of a SB 350ci piston ?
5.7 inch length rod in a SB chev

KLX650 inside diameter of the small end of the connecting rod is .945 inches

KLX650
Compression Height29.5 mm
= 1.161 inches

What sort of power you looking for Fogo ?
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Old 09-14-2013, 06:02 AM   #34
Fogo72 OP
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Quote:
Originally Posted by KASUYAHO View Post
Just playing around looking at different options
Your KLX
Bore 3.937
Stroke 3.27
Longer stroke 3.50
42.7 CI = 699cc
Specs are close to 360ci mopar 4.00 bore 3.58 stroke, 6.123 rod length
Wrist pin dia .9842 in

Chev SB from memory has a .750 wrist pin dia,
350 chev has a 4 inch bore, same as 400 chev, which has different pistons
has it has a different compression height.
Forget what the compression height of a SB 350ci piston ?
5.7 inch length rod in a SB chev

KLX650 inside diameter of the small end of the connecting rod is .945 inches

KLX650
Compression Height29.5 mm
= 1.161 inches

What sort of power you looking for Fogo ?
Your correct with your numbers, I am also a member of the KLX yahoo group world wide and there is a guy who is running a chev piston in a KLX and it has 15000 klms on it with no probs. Would have to be flat top piston as chevs have 2 valves and KLX 4 valve. Wossner pistons will build what ever piston you want.
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Old 09-14-2013, 06:08 AM   #35
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Old 09-14-2013, 07:08 AM   #36
KASUYAHO
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Quote:
Originally Posted by Fogo72 View Post
Your correct with your numbers, I am also a member of the KLX yahoo group world wide and there is a guy who is running a chev piston in a KLX and it has 15000 klms on it with no probs. Would have to be flat top piston as chevs have 2 valves and KLX 4 valve. Wossner pistons will build what ever piston you want.
I don't know about Wossner pistons but most custom piston makers use a blank from TRW.
Then make the piston to suit your application.
You can fly cut the valve reliefs yourself as we used too.
.125in from memory was the minimum crown thickness we would go with our pistons on our race engines, less than that and we would have had troubles burning holes in them but that was not for an endurance engine.

BME was the choice of piston years ago we used, but that changes for reasons.

What would be the connecting rod ratio for the KLX ?
we used to run around 1:85 for our small block engines, stock chev was 1:72 or there about, it's been over 20 years now.
Small block mopars were a better design and FORDS blow up

Have fun
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Old 09-14-2013, 04:47 PM   #37
Doctor
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Location: At the knackery sellin a coupla horses
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Quote:
Originally Posted by KASUYAHO View Post
Just playing around looking at different options
Your KLX
Bore 3.937
Stroke 3.27
Longer stroke 3.50
42.7 CI = 699cc
Specs are close to 360ci mopar 4.00 bore 3.58 stroke, 6.123 rod length
Wrist pin dia .9842 in

Chev SB from memory has a .750 wrist pin dia,
350 chev has a 4 inch bore, same as 400 chev, which has different pistons
has it has a different compression height.
Forget what the compression height of a SB 350ci piston ?
5.7 inch length rod in a SB chev

KLX650 inside diameter of the small end of the connecting rod is .945 inches

KLX650
Compression Height29.5 mm
= 1.161 inches
where did ya copy/paste this from




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'must be the 'ooooohhhhhmmmmm' factor kicking in'
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Old 09-14-2013, 05:16 PM   #38
GSXR
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I just called my engine builder & he said Fords only blow up when built by novices.
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Old 09-14-2013, 05:30 PM   #39
DRjoe
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Fogo do it properly and fit this

http://m.ebay.com.au/itm/380714630818?cmd=VIDESC
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Old 09-14-2013, 05:59 PM   #40
Fogo72 OP
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Quote:
Originally Posted by DRjoe View Post
Fogo do it properly and fit this

http://m.ebay.com.au/itm/380714630818?cmd=VIDESC
Look you lot, its up to me on this website to provide the entertainment.
We spend lots of money
You follow the build
The thing explodes.
Everyone cheers, just like the old Roman days.

Remember the Longest day ride last when everone was cheering me on and you thought that we were going to make it, then the engine self destructed.
Then a roar from the crowd could be heard as I took a bow.
Now thats entertainment for you couch sitters.
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Old 09-14-2013, 06:54 PM   #41
Doctor
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Location: At the knackery sellin a coupla horses
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Quote:
Originally Posted by Fogo72 View Post
Look you lot, its up to me on this website to provide the entertainment.
We spend lots of money
You follow the build
The thing explodes.
Everyone cheers, just like the old Roman days.

Remember the Longest day ride last when everone was cheering me on and you thought that we were going to make it, then the engine self destructed.
Then a roar from the crowd could be heard as I took a bow.
Now thats entertainment for you couch sitters.
mate


we all spend a bit of time slapping the keys and no not the bike one's


from the lounge , loo (gotta love wifi) the deck , doesnt matter where
we salute you


even though ya didn't make the TTT's

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'must be the 'ooooohhhhhmmmmm' factor kicking in'
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Old 09-15-2013, 03:47 AM   #42
KASUYAHO
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Location: Aussie Land
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Quote:
Originally Posted by Smithy69 View Post
I just called my engine builder & he said Fords only blow up when built by novices.
That's why you got an engine builder Smithy

Sorry Fogo,
back to the KLX700 hot rod
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Old 09-15-2013, 01:27 PM   #43
troy safari carpente
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Location: "Pearl of the sound" - f5ederation of scandwegia
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To buggery with the top fuel & drag queen reminiscing...

Quote:
Originally Posted by Fogo72 View Post
Well guys, its an idea that we have been kickin around the shed for some years. To take a KLX650R engine out to 700cc with a home made 3mm stroker crank while still allowing it to rev with the STD chome bore or put the 2mm oversize bigbore kit on it and take it out to 750cc.
Junior piped up and said "Dad if you pull this off I will race it at Condo next year. So its all GO.
Yesterday I pulled two old KLX650R's out of the scrap heap and got them stripped down to a bare frame.


Out of the 2 frames one is better than the other, I have sent both away to be sand blasted and crack tested then the one we choose to use as the race bike will be lightened as much as we can and the other will end up as Bike 3 for my son Mark who is 15 and soon to be inducted into the KLX losers hall of fame.
Both frames we be painted in Kawa green to match the 2002 colours.


I had a meeting yesterday with the guy who is machining the crank about how he plans on going about this task.
He is going to weld up the lower half of the Big end bore hole and rebore it 3mm off centre which will give it a extra stroke of 6mm overall taking it from 83 to 89mm and 100mm bore.




Cheers Fogo...
Quote:
Originally Posted by Fogo72 View Post
Here are the forks that I bought off fleebay in the States, on a plane as we speak. gunna look sweet.

More about the revival of these premium grade 90's desert sleds... pleeeease.
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Old 09-15-2013, 04:02 PM   #44
Fogo72 OP
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Location: NSW
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Quote:
Originally Posted by troy safari carpente View Post
More about the revival of these premium grade 90's desert sleds... pleeeease.
Thanks Troy for getting us back on track.

Back to how much power I expect to get out of this thing.
There are reports worldwide of 65hp KLX650's , But there is absolutely no proof as know one can produce a Dyno sheet. So lets be realistic here.

Kermits new engine,
KLX650C electric start in an "R" model bike.
Spec, 38hp at the flywheel
Kermits specs,
STD bottom end
The electric start engine runs an alloy barrel with a cast iron sleeve pressed into it instead of the chrome bore (Nikisil)
20" thou was shaved off the barrel to raise the compression
The bore is STD 650cc
Wossner piston
STD 40 vac carbie with a 150 jet
Port and polished cylinder head and major reshaping of the combustion chamber to dome it out more which would have lowered compression a bit hence the shave on the barrel.
STD valves
STD cams
STD exhaust header
Staintune muffler with no baffle

Kermits result on the Dyno was 45hp at the back wheel. The Dyno operator said a brand new CRF450R straight off the showroom floor will pull 46 at the back wheel. So not a bad effort. Does it feel like your riding a CRF450, NO. All Kermits power is made from 1500 rpm to 4500 rpm, real deep down lugging tractor power, which is what I wanted to ADV ride around the place with a 50 kg load on his back.

So being realistic here, mods that will be done
"R" model engine, lighter rotating parts, flywheel ect compared to the "C" engine
STD bottom end, bar the 3mm stroker crank taking it to 700cc
STD 650cc Nikisil barrel, unmolested, raised with a 2mm base plate shim to get away from buying a new custom conrod and keeping the crank angle lower.
100mm STD Wossner piston with 1mm shaved off the top.
TOTAL SEAL piston rings
STD cylinder head with exhaust ports polished only
Going to purchase a new Kehin 41mm FCR carb which we have never tried on one of these engines.
1/4 bigger dia stainless custom header pipe into the Staintune muffler
Adjustable cam gear timing, Manual.
Hot cams.

So what do you guys recon we can get out of this,
I was hoping 55hp, am I myself.
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Old 09-15-2013, 04:40 PM   #45
rmhrc628
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Joined: Feb 2006
Location: The high country VIC
Oddometer: 2,483
Quote:
Originally Posted by Fogo72 View Post
Thanks Troy for getting us back on track.

Back to how much power I expect to get out of this thing.
There are reports worldwide of 65hp KLX650's , But there is absolutely no proof as know one can produce a Dyno sheet. So lets be realistic here.

Kermits new engine,
KLX650C electric start in an "R" model bike.
Spec, 38hp at the flywheel
Kermits specs,
STD bottom end
The electric start engine runs an alloy barrel with a cast iron sleeve pressed into it instead of the chrome bore (Nikisil)
20" thou was shaved off the barrel to raise the compression
The bore is STD 650cc
Wossner piston
STD 40 vac carbie with a 150 jet
Port and polished cylinder head and major reshaping of the combustion chamber to dome it out more which would have lowered compression a bit hence the shave on the barrel.
STD valves
STD cams
STD exhaust header
Staintune muffler with no baffle

Kermits result on the Dyno was 45hp at the back wheel. The Dyno operator said a brand new CRF450R straight off the showroom floor will pull 46 at the back wheel. So not a bad effort. Does it feel like your riding a CRF450, NO. All Kermits power is made from 1500 rpm to 4500 rpm, real deep down lugging tractor power, which is what I wanted to ADV ride around the place with a 50 kg load on his back.

So being realistic here, mods that will be done
"R" model engine, lighter rotating parts, flywheel ect compared to the "C" engine
STD bottom end, bar the 3mm stroker crank taking it to 700cc
STD 650cc Nikisil barrel, unmolested, raised with a 2mm base plate shim to get away from buying a new custom conrod and keeping the crank angle lower.
100mm STD Wossner piston with 1mm shaved off the top.
TOTAL SEAL piston rings
STD cylinder head with exhaust ports polished only
Going to purchase a new Kehin 41mm FCR carb which we have never tried on one of these engines.
1/4 bigger dia stainless custom header pipe into the Staintune muffler
Adjustable cam gear timing, Manual.
Hot cams.

So what do you guys recon we can get out of this,
I was hoping 55hp, am I myself.
Won't the larger dia header soften the lower end ?

The fcrmx will really waken the bike up.

Be aware there are 2 ways to go with fcrmx - bolt on bell and glue on via a noss adapter.

Beauty of running an fcr is normally you can go to better mx type cables and throttle housing so lighter pull.
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