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Old 09-13-2013, 03:58 AM   #1
Fogo72 OP
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KLX700 Project

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...
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Old 09-13-2013, 04:12 AM   #2
rmhrc628
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Old 09-13-2013, 04:14 AM   #3
Fogo72 OP
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Specs for the bike

Last night I bought a set of forks and triple grips off a KX250F 2007 model out of the States for $400 and they are on their way.
We plan on running a complete KX250F front end.
I have been talking to a mob Overseas about purchasing a KTM690 2008 rally replica front fairing that we are going to graft onto the front of the bike. We want to get this part right as a lot of mods are going to be done and a lot of cutting, shutting and adding fiberglass. Then a final mould will be made of the finished product and all 5 bikes will end up with this front on it.
Port and polished head
41mm FCR carb
New custom header pipe
Race cams out of Kermit to go in.
We still run the 17 litre Acerbis tank so the fairing has to fit around that some how.
Meanwhile we have 3 second hand engines on the bench to disassemble and salvage to best we can for one good Donk.
Cheers Fogo..
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Old 09-13-2013, 04:17 AM   #4
Thunder Dan
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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.








Cheers Fogo...
It's official, you're weird

Na, this is awesome, really keen to see what Mr. R can do to that crank.


Cheers,

Dan.
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Old 09-13-2013, 04:21 AM   #5
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shit hot fogo. love a good build thread
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Old 09-13-2013, 05:16 AM   #6
panhead_pete
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Wow what a great project. Any thoughts of lightning the rotating assembly on the race motor?
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Old 09-13-2013, 05:48 AM   #7
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Originally Posted by panhead_pete View Post
Wow what a great project. Any thoughts of lightning the rotating assembly on the race motor?
I think we would have to be really carefull trying to take weight off the crank and balance weight, get it wrong and it vibrate to bits. Engine blue printers would be the people to see, maybe the guys who do all the Go cart race engines. But no endless budget here.
We are going for the raised barrel idea instead of getting a shorter conrod made from Corrillo. I might get a base gasket cut out of stainless by a water jet and raise the barrel 2 mm and mill 1mm off the top of the piston to get a round the stroke difference, that way the crank angle wont change too much I have been told, and it decreases the side load on the trust sides of the liner.
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Old 09-13-2013, 02:57 PM   #8
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Old 09-13-2013, 06:07 PM   #9
Oz Nutter
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http://www.gumtree.com.au/s-act/klx650/k0l3008838
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Old 09-13-2013, 06:44 PM   #10
dunc59
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these might be different to the fairing your looking for as well
just got to keep looking as its not in order lol
fairing replica
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Old 09-13-2013, 07:33 PM   #11
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How about a DR Safari tank and fairing


it would look fecking fast
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Old 09-13-2013, 07:50 PM   #12
Fogo72 OP
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Originally Posted by Doctor View Post
How about a DR Safari tank and fairing


it would look fecking fast
The KLX has not got a single backbone frame so it wont fit.

Hey guys, I need to send a base gasket to somewhere that can scan it and cut some new ones out in a water jet, out of different thickness stainless sheet. like 1mm , 1.5mm and 2mm. Anyone know somewhere that has a water jet that could do that?
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Old 09-13-2013, 07:59 PM   #13
outback jack
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Quote:
Originally Posted by Fogo72 View Post
The KLX has not got a single backbone frame so it wont fit.

Hey guys, I need to send a base gasket to somewhere that can scan it and cut some new ones out in a water jet, out of different thickness stainless sheet. like 1mm , 1.5mm and 2mm. Anyone know somewhere that has a water jet that could do that?
Try here Fogo. http://www.kilner.com.au/
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Old 09-13-2013, 08:06 PM   #14
Rider 101
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laser

The company I work for has a laser division. I have seen some of their work including laser etching and it is pretty impressive.

http://www.rcrtom.com.au/index.php/o...-laser-cutting

They have a workshop in Sydney if that helps.

Quote:
Originally Posted by Fogo72 View Post
The KLX has not got a single backbone frame so it wont fit.

Hey guys, I need to send a base gasket to somewhere that can scan it and cut some new ones out in a water jet, out of different thickness stainless sheet. like 1mm , 1.5mm and 2mm. Anyone know somewhere that has a water jet that could do that?
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Old 09-13-2013, 09:42 PM   #15
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Quote:
Originally Posted by Fogo72 View Post
The KLX has not got a single backbone frame so it wont fit.

Hey guys, I need to send a base gasket to somewhere that can scan it and cut some new ones out in a water jet, out of different thickness stainless sheet. like 1mm , 1.5mm and 2mm. Anyone know somewhere that has a water jet that could do that?
once upon a time i knew a fellow that did just what you want to do
he cut a one piece alloy base gasket, it worked a treat and he did it by hand tools.
it was a Kwaka 500 tripple
so alloy works well
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