KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Fri Nov 03, 2017 9:35 pm

KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES 106.jpg
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KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES 107.jpg
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KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES 108.jpg
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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Sun Nov 05, 2017 5:54 pm

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


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 109.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 109.jpg (370.9 KiB) Viewed 71 times
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.


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 110.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 110.jpg (199.9 KiB) Viewed 71 times
So a little material has to removed from the starter housing lip area.



KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 111.jpg
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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Sun Nov 05, 2017 5:56 pm

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..


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 112.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 112.jpg (249.83 KiB) Viewed 70 times



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

KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 113.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 113.jpg (347.7 KiB) Viewed 70 times
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.


20171105_100553.jpg
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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Sun Nov 05, 2017 6:01 pm

After a little milling it fits like a glove..


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 114.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 114.jpg (292.31 KiB) Viewed 66 times

KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 115.jpg
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KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 116.jpg
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KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 117.jpg
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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Sun Nov 05, 2017 6:03 pm

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 :shock: 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..


20171105_100449.jpg
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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Thu Nov 09, 2017 3:22 am

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


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 120.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 120.jpg (309.41 KiB) Viewed 53 times

KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 121.jpg
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KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 122.jpg
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KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 123.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 123.jpg (227.74 KiB) Viewed 53 times
Clearly I need to step up my game...
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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Markee757 » Sat Nov 11, 2017 5:52 pm

Wild work!

Where you getting your hardware?

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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Sat Nov 11, 2017 11:07 pm

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
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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Tue Nov 14, 2017 11:22 pm

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


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 124.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 124.jpg (385.47 KiB) Viewed 28 times
Next thing is to get rid of the splash guard for the filler plug.. :o
Cut number 1.


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 125.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 125.jpg (516.78 KiB) Viewed 28 times
Cut number 2


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 126.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 126.jpg (404.21 KiB) Viewed 27 times
A little mill/drill work..


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 128.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 128.jpg (366.51 KiB) Viewed 28 times
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KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 125.jpg
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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD

Post by Sandblaster » Thu Nov 16, 2017 3:43 pm

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


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 130.jpg
KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 130.jpg (454.49 KiB) Viewed 21 times
I have never tried this product... We'll see how it works..


KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 129.jpg
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