BUILDING A STREET LEGAL KX500 SUPERMOTO

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I know I know.... I just got this thing together and running....
But I just can't resist...
So...... Out with the old...

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KX500 ENGINE SWAP 2.JPG (140.65 KiB) Viewed 7080 times

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I'm waiting for all my gaskets to come in and I'm twitching to get the show on the road....
Today I started looking at my stock cylinder
And you know, I can't port it or deck it without having it re-plated.
So, I'm gonna do what I can without porting.
What can be done?
Quite a bit....
Take a look at the cylinder before I started messing with it..
Stock bridges which were welded before plating, looks kinda rough..

kx500 2001 cylinder clean up 1.jpg (177.75 KiB) Viewed 7063 times

Stock transfers and stock floor ports.

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So, I whipped out the die grinder and GGGGGGGGRRRRRRRWWWWHHHHEEEEE!!!!!!

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I can't use this thing.
Sure, it moves a lot of material but I can't hang onto it very well...
So, I grabbed my Dremel, I know some of you hate it but I'm not set up with air tools..
And, after a while they will move material.

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And don't forget the eye protection as well as the lens correction for those of us who can't see anything unless it is at least 3 feet in front of us

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Now were starting to get somewhere..

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These are looking better too...

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So far I have about an hour into the project.
I'm about half way done so it's not a bad job and if I can do it, you can too..

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I just had a guy at another forum ask me why I was doing this to my cylinder:
What exactly are u doing? How will that benefit? Thanks!

This diagram is of the intake bridges and how air flows around them in the stock configuration.

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The air/fuel mixture hits the face of the blunt bridges causing the air to swirl around.
This actually narrows the channel that the air can flow through undisturbed.
So, you are loosing air velocity as well as the volume of air entering your engine.

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After cleaning up the bridges you greatly free up the non disturbed air flow maintaining maximum air velocity and volume..

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Here is some porting tools I use.

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More work..

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More work..

2001 kx500 porting.JPG (65.11 KiB) Viewed 7057 times

I may have under estimated my time a bit... I worked on it for another hour today and I still have a LONG way to go

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I was accused of having OCD.
So?

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Still finishing the last of the cylinder clean up.
But for now I'm finishing the bottom end...
What we have is all the oil passages have been cleaned up, all mating surfaces have been lapped with Timesaver, bearings, seals, gaskets, shift forks, shift drum, and every snap ring, has been replaced.
The crank has been welded, trued, and balanced and rebuilt, using a IMS Pro rod.
Windowed Wossner piston, stock bore, fresh plate.
Transfers, bridges, and exhaust port, has been cleaned up.
Water ports have been cleaned up and the impeller clearance mod is done.
2 angle squish band with decompression on the head.
The rest is just glitter...
So, it should be just a nice, smooth, stock motor with some cleanup.
How will it run?
I should find out very soon.

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The top end is back on.
So tomorrow I will take the chassis out back and wash it really good.
Also, I'm going to pull my air box off the bike and completely clean it inside and out.