Motorrads Jeff Ward engine build series 2

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Marco810

Holly crow, those exhaust ports are huge!. Looking good

Motorrad

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81cr450

Where did you get vf2's ? & I really like that zipty trick for the rings. Also did you have to cut your pin length down?

Motorrad

V2's came driectly from Moto tassari... after I bitched a bunch about their V3's.. (You can get them at OEM-CYCLE.COM)

Which pin.. wrist pin, or head pin.....

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After sticking the Mitatoyo guage on the deck.. and a degree wheel on the PORTS... Decided I needed a bit more UP on the jug.. but stock .020 gasket was too much...

Soooo.. I took all the gasket material off one side of the gasket.. (it is going up against another rubberized gasket, so no problem with seal). and whala... exactly where I needed..

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Deck hight after Gasket fix.. Positive .005"

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81cr450
Wrist pin, to get it so the circlips would go in, my 90mm wouldnt. Thats Great to know , bitchin gets you vf2's. I'm gonna give that a go. Radiator showed up today

Motorrad
Thought I was gonig to have to as well.. But I gave it a rap with a brass punch.. and SMALL hammer.. and it seated in on the other clip.. (pin is tapered)
the other clip snapped right in after that...
Oh.. BTW people.. the wossener wrist pin is LIGHT! only 72ish Grams (or was it 74...) either way.. its about 10 grams lighter than stock..
Decided Im building a On the bench tester for the titanium pin coating.. to see how it holds up... instead in the motor

Goat
Every time I check this thread it makes me want to build mine better than stock. It's barely broke in by the way. I may have 40 hours on it which is sad for 2 years after total rebuild. I'll be on it more this year for sure.
Are you running 1.5 base gaskets then, since you shaved off some of the one to make it thinner?

Motorrad
Technically there are 2 normal base gaskets, the one I modified, and one more spacer of undisclosed thickness (trade secrets)..
so... there are 4...

Goat
Ahh ok. I see the other "undisclosed thickness" spacer now that you said something.
Are you building a custom pipe for this beast, I hope?

Motorrad
Yes... as soon as I get back from my 6month long motorcycle ride

Left to right.
1987, Light MZB, 88-04

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jgturbo
Are you planning on lightening the flywheel?

Motorrad
Going to run the 26oz MZB one... so roughly 1LB less than stock...

jgturbo
What's your reasoning behind a lightened flywheel? I've got an opinion on the subject, but I'd like to hear yours first

Motorrad
Simple.. It's Easyer to add weight that remove it...
That being said.. I like the light one for when I'm on the supermoto track.. Or the street. (remember my bike is plated)... As it comes out of a corner like you shot it out of a cannon evil
In dirt.. I have enough (ward) flywheel weighs cut to add 2.5 lbs to my setup... Half a lb at a time... (when I trail ride it durring summer, I LOAD HER UP)
Weight on my old flywheel New ones are still at work

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14.5 : 1 uncorrected compression

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jgturbo

Your reasoning makes sense to me. The ability to add or take away weight is handy. I just wanted to get your take on the matter because most people don't fully understand the role of a flywheel in an engine. I'm guessing you do though.

A piston engine doesn't have a continuous torque output like, say, a turbine engine would. There is a torque spike during each power stroke and then a valley where you're dependent on the inertia of the rotating components to bring the engine back around so you can have another power stroke. One of the places this inertia is stored is in the flywheel. The average of these peaks and valleys is the torque output of the engine. A light flywheel will make tall peaks and low valleys. A heavy flywheel "smooths" the graph and brings both the peaks and valleys closer to the average torque value. The smoothing of the torque graph will result in less fatigue in internal engine components because it decreases the magnitude of the cyclical loading.

That's the way I see it. But I'm sure you already knew all that. smiley

I totally understand modifying the weight to achieve the desired characteristics for different conditions. Just wanted to make sure you weren't in the "lighter is always better" crowd.

Carry on!

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jgturbo
Don't these bikes come stock with an 8.5:1 ish compression ratio? Are you really adding 6 more points, or are we talking about different methods of CR measurement? I know four strokes inside and out but I'm rather new to the world of two stroke engine theory.
Thanks!

Motorrad
The numbers in the "book" are corrected... Im quoting Uncorrected numbers...
also.. keep in mind. the K5 has a heavy rotating assembly to start with... compaired to anything modern.

Say BUH----BYE..
P.S. Can you find whats wrong with this picture... that I noticed the second I dropped the head on...

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And... we again... Like I tell all the 4 poke guys ... have "a STOCK Kx500 motor"

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alward25
you have a pin in the head and cylinder, is that the "new' squish angle?? Need Cometic to cut a new gasket for you

Motorrad
The new 180 Degree compression release modification.

Brute
Are all the cooling holes open? Seems like there should be a couple more holes in the head gasket? Two pins would be a problem... Lots of head gasket goo!

Motorrad
yes they are all there.. same as stock.. the copper gasket just seems to make it look like there is less for some reason.. I thought the same when I first had it in my hands.. till I compared to another...
Was ready to light her off tonight..
till I realized... I burned all my extra coolant up in the last race feeding it to her... rolleyes
guess the neighbors dont get to hear a K5 at midnight like normal...
tomarrow before noon... that is the goal..
Oh BTW.
Thank god for Larry Weichman.. even with the compression release.. this thing is fun to kick.. without.. its like kicking a brick wall... who would have guessed.. Kx550 at 14.5:1 is hard to kick...

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Goat
Holy S*$T that is some ridiculous compression lol
Will it do 10K rpm ??

Motorrad
It did before.... with less port timing... and more "corrected" compression...

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81cr450
I would have guessed it's HARD to kick as my foot is bruised & my shoe is sliced right up the side. & its weird cause dead cold you get one mild kick but the pressure builds from there & it just gets worse once its hot even. Good thing it starts easy. Decomp is next on the mods list

Motorrad
Vroom.... 2nd kick. 1st kick.. i was lazy and didng get it all the way through..

Goat
Great news. Now where's the vids!? lol

Motorrad
1st heat cycle down...
deffinatly rich. I knew the Big Bore would make my jetting rich.. but didnt expect this much...
CHT came up to about 158... and hung there... grin grin
just retorqued everything.... nothing moved.... so far..
heat cycle #2 comming up shortly...
Then I drain my "tranny flush" oil out...
then I go for a ride.

Motorrad
heat cycle #2... what I thought was left over coolant from bleeding head... wasnt.... wheeping coolant from head...
Head is off. On bench..
I already knew what the problem was before I took it off.... (somthing I was going to do before I put it together. but didnt)
confirmed it..
Walking out the door RIGHT NOW... to my grandmothers 89th Birthday party..
will post more later... and take pictures of how to fix it..

RoostDaddy
my guess would be to heat the copper head gasket first. Or throw it away and use a Cometic S/S

Larry Wiechman
Dowel pin bottomed out?

jgturbo
How are you sealing the copper head gasket? Got a stainless o-ring and matching groove for compression and some sort of goo (hylomar works wonders) for coolant?

Motorrad
Head studs pulled a bit of material...
I normally countersink them... But didn't this time... Being in a hurry bites ya..

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Motorrad
Okay... Like I said... I normaly do this... for some reason or another.. I didnt this time... so I get to do it with the motor together... rolleyes
shopvac and a 90 makita is your friend.

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