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Only $10 for all 2024 SX, MX, and SMX series (regularly $30).
I own 4 systems, one for each of my KX500's
Makes having a Supermoto a piece of cake..
Fresh out of the Vapor Blaster and the oven...
Prepping it for the machinist Adam Millar who will re-cut the head, add a decomp, and change the location of the water outlet.
For some reason he likes them clean before he works on them
Yes, the guy cutting my head is building the bike I'll be running against so he knows a lot about my engine... But not everything..
I will have to do a few mods to pipe so that it will fit around the E-start but I don't want to put to much effort into it until I decide if I'm going to use it or not...
The Shop
As far as I know these are the first billet KX500 engine cases on the planet...
My race team had talked about developing billet KX500 engine cases just to give us the option as new cases are no longer available from Kawasaki.
I'm glad that TSR stepped up and made it happen.
They should retail for about 1750 USD when they come to market...
And yes, that's a hydraulic clutch.. Lol
In fact they made several mods for me already, but moving the mounts on the cases would take them extra time so for this build it was easy enough for me to move the mounts to fit the cases.
The other part is because it's KX500 against CR500 in a International spotlight
I know I have my work cut out for me because Adam Millar is a mechanical genius..
I am no where near his level...
But I do have a few small tricks up my sleeve that should prove to make it a interesting competition.
Plus I'm starting with a advantage... KX500
I just hope I can do this build justice to put in a good showing...
Time will tell...
You're killing it
After seeing the quality of their work I wish they would.
I appreciate that...
You can see here where they all hit.
My solution is to get a new cone pipe made.
But I don't want them to use my fancy pants electric starter for a template to work around.
When all else fails I turn back to wood working.
It bolts right up and simulates the Electric starter perfectly
It's crude but effective
Now I can send the template to the pipe maker and they have something to work with..
This is a minor issue that will only effect you if you are using the TSR cases with the Panthera E-Start.
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.
So a little material has to removed from the starter housing lip area.
Pit Row
In this pic you can see the area of the Engine cases that is interfering with the starter housing.
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.
Is this gonna be your "daily driver" or what do you intend to ride with this bike?
The frame and engine stuff is pretty genius, shit is overwhelming to me. Id really like to learn all the fab stuff.
To be honest it's like being struck by lightning.
It's really cool... but kinda scary
I plan on riding it hard... but taking good care of it.
It will likely see some woods occasionally but likely desert and dunes is where it will live.
The bottom end will stay with this chassis.
The top end may get moved around depending on how I like it when it is done.
I have some really cool motor mods that I've dreamed up so we'll see how it works out.
The goal is to maintain or increase stock bottom end power but have significantly more top end...
Go ahead... Flame me... I love it... Lol..
I've talked to a few industry leaders including Stewart who has the current KX500 Land speed record about my approach and although none have tried it themselves they say that my idea's should work... But time will tell..
Looks like 5 minutes with a file / a few seconds with a linisher to rectify it. Unless I've missed something, I'd not bother with saddling it up to my mill myself, but, I've fabricated things for decades now, so things like that don't faze me. But, on the other hand, my 'puter or 'phone goes 'Ping', and I freeze with fear......
Have you checked the intermediate / back torque limiting gear for 'true'? (if you recall my video from a few pages ago).
I'd be really interested in if they've made decent part(s) yet.
The noise from my massively out of wack (2 of them) parts is horrendous, and they are bound to fail / cause other parts to fail. I've not had an answer from Panthera on how bad it is and, when they will provide part(s) that are safe to use.Those Gears, the ES motor carrier/ sprocket cover that fits so badly , and a sprag clutch / rotor (that won't rub against each other without the thrust shims I've had to fit) are dreadful - They seem not to give a damn.
See how thin the 'ears' of the gear carrier case are - mine arrived damaged, and with 7mm holes to accommodate 6mm bolts. I made a reinforcement plate to take care of both problems - problems, together with the other Numerous , far worse problems that should never exist on something that cost over $2,500.
PS : re that breather they have.
It's neat little thing,and it's higher than the std case 'slot'.
But , if you plan to get near any water, you'd be wise the replace that fitting, which If I recall correctly is 1/8"NPT, with a 10mm x 1mm banjo bolt and fitting to take a hose. I live by a River and have many creek crossings, so I 'submarine' to the airbox top fairly often. A line up into the back bone, with my topmount airfilter/ airbox I have, and you have non watered / emulsified oil ignition / gear casing.
A 10mm x 1mm tap will go straight in, it's pretty much the same initial pitch as the 1/8"NPT, without the taper, so it 'cuts' in perfectly. Just make sure you don't use an overly long banjo bolt, that may interfere with the crown wheeled gear.
I didn't use a hand file but I used my elcheapo milling machine..
I have not checked the gears yet but intent to in the near future.
I did note that they used some very short bolts for the cover so I ordered some longer bolts.
My general rule is that with aluminum I like to have at least twice the diameter of the bolt in thread engagement.
These were not even close... And since I love titanium I'm sure you can guess what sort of bolts I ordered
I don't have any water crossings where I generally ride (Desert and dunes) but I think it is something that I should take a close look at.
I really appreciate all the heads up that you have given me. Hopefully I can cobble something together that actually works
What neither of us has done yet is run it
But we'll get to that soon enough.
The TSR CR500 cases are awesome as well and they have been totally tested and they work great.
Adam Millar the builder of the CR500/KTM hybrid that I'm competing against is also using TSR cases in his build...
Post a reply to: JUST ANOTHER 2016 KTM 250SXF CHASSIS KX500 ENGINE CONVERSION GONE MAD!