Mutant Motor Xr/klx

storminnorman07 · Mar 17, 2011

i have had a number of guys ask me about the mutant motor i am doing. i had it posted on here for a while then took it off. seems like things have died down so i'll attempt it again. i'm just going to start it off where i left off on prior thread i had post.

i revised the crank a lil and reduced weight even more with weight savings on rod about a lb lighter than the stock xr 100 crank

stock on bottom cut halve on top

piston with 55mm stroke 100mm rod.

cut down to give myself .020th clearance

manforrilla · Mar 17, 2011

dang son... just dang...

storminnorman07 · Mar 17, 2011

i didn't look the cases over well before doing the welding and machine work. it wasn't til after i did all the work did i realize i had a oblonged shift shaft hole so i had to make a bushing for that. some pics of the spotfacing, drill, tapping and setting one timing chain slide in, cam gear from a xr 80 w/ hole relocated for klx cam

pic 1 and 2 bushings for timing chain slide

pic 3 and 4 other slide cut down to fit the takegawa head

pic 5 shows both slides in with adjuster in

pic 6 prepped intake for weld

pic 7 welded to mill down and put holes for carb boot

storminnorman07 · Mar 17, 2011

intake milled down and holes tapped for rubber boot

left is revised bowl right side old port. new bowl is over a mill bigger in diameter and more distinct d shape

lil better view of the old smaller bowl

both bowls complete

welds all prettied up

finished revised port

match to boot

cutting it close?

storminnorman07 · Mar 17, 2011

trail fitment of exhaust after hacking a new header up

lil closer view

another close call

exhaust finished up

almost got the stator plate done just need to get the crank in and see where i need the stator plate center punch then knock some holes in it and tap.

storminnorman07 · Mar 17, 2011

before pic of tranny rack

finished tumbed tranny gears

AngryDirtbikers17 · Mar 17, 2011

So sick man

50rider340 · Mar 23, 2011

Honda should hire you to work for them.

507 brett · Mar 23, 2011

too crazy..

storminnorman07 · Mar 23, 2011

50rider340 said:
Honda should hire you to work for them.

lol don't i wish

skipbuysparts · Mar 23, 2011

this is going to be the sickest xr 80 on the planet

Adam z50+R · Mar 23, 2011

Some Serious Skill ,Ingenuity and Effort involved

Regarding the gear tumbling process

this is to deburr the gears, so that they mesh together better, with less resistance/friction,, hence reduce heat/free up power?

from memory Yoshimura offer something like this, they call it ISF,

found on google

http://www.yoshimura-rd.com/t-Engine_Services_ISFProcess.aspx

after reading the article it answered all my questions:

Why the ISF Process® is important to any application:

•Less inertia = Less friction = Less fuel consumed

•Reduction of friction of metal to metal contact parts = Less wear and contact fatigue

•Lower operating temperatures = Increased power output and efficiency

•Increased power density = Options of larger engines or smaller transmissions

•Increased durability = Lower replacement costs and fewer failures

Between starting and finishing this post i've learned lots ,worth sharing

Looking forward to updates, Very Interesting

Mx353 · Mar 24, 2011

Adam z50+R said:
Some Serious Skill ,Ingenuity and Effort involved

Regarding the gear tumbling process

this is to deburr the gears, so that they mesh together better, with less resistance/friction,, hence reduce heat/free up power?

from memory Yoshimura offer something like this, they call it ISF,

found on google

http://www.yoshimura-rd.com/t-Engine_Services_ISFProcess.aspx

after reading the article it answered all my questions:

Why the ISF Process® is important to any application:

•Less inertia = Less friction = Less fuel consumed

•Reduction of friction of metal to metal contact parts = Less wear and contact fatigue

•Lower operating temperatures = Increased power output and efficiency

•Increased power density = Options of larger engines or smaller transmissions

•Increased durability = Lower replacement costs and fewer failures

Between starting and finishing this post i've learned lots ,worth sharing

Looking forward to updates, Very Interesting

JGR does it also. They did the gears in my rm125 its actually a super sick mod

storminnorman07 · Mar 24, 2011

Adam z50+R said:
Some Serious Skill ,Ingenuity and Effort involved

Regarding the gear tumbling process

this is to deburr the gears, so that they mesh together better, with less resistance/friction,, hence reduce heat/free up power?

from memory Yoshimura offer something like this, they call it ISF,

found on google

http://www.yoshimura-rd.com/t-Engine_Services_ISFProcess.aspx

after reading the article it answered all my questions:

Why the ISF Process® is important to any application:

•Less inertia = Less friction = Less fuel consumed

•Reduction of friction of metal to metal contact parts = Less wear and contact fatigue

•Lower operating temperatures = Increased power output and efficiency

•Increased power density = Options of larger engines or smaller transmissions

•Increased durability = Lower replacement costs and fewer failures

Between starting and finishing this post i've learned lots ,worth sharing

Looking forward to updates, Very Interesting

well stated. that's the goal of it. the yosi isf process is what got me thinking about doing it. last year at the trade show they had a 450 rack sitting there so you can fondled it. so i'm looking it over and one the reps came over so we talked for a lil bit about it and i grabbed a card. when i got back the following week i called and did some more disscussing about the process and have they done a mini rack, if they have was it a china one how did it come out? back when i did the ti valved yx 4 valve i had plans to do steps to see what each step gave me as far as hp gain. well one of the things i really wanted to do next was the tranny rack cause all of the china gears are chit they are nothing less of two files mating together. well at that point in time they have not did a mini rack let along a ching one but really wanted to. they prefer a new tranny rack but have done lightly used ones. i started to lose interest in that project when i started reading about cr/xr conversion builds. i built one for my lil bro and took it for a ride and instantly fail in love. sold just about all my pitbike stuff and started on this. when i started seeing things come together that getting the klx top end to work on the xr bottom i decided i was going to do all the things i was going to do with the yx bottom on this xr bottom. being that i was using a old xr tranny and just about everyone that has ever owned 80/100 can attest they don't get rode lightly. with that said i really didn't feel like buying a brand new rack to send to yosi so i called around see what other companies offered and every where else strongly recommend a new or or lightly used tranny. so i bought myself a small tumbler/vibrator and some ceramic media and did it myself. i honestly did not have high expectations for the lil tumbler/vibrator but as you can see from the pics post above it does a pretty good job. the only downside to it. its small so i can only do 1 rack at a time and it don't do it in a hurry depending on how rough the gears are 24-72 hours of run time per rack. but i guess if you figure shipping it to yosi in cali i'm on the east coast then the time it takes them to do it plus shipping back its about the same time frame

johnson05 · Mar 24, 2011

Beautiful work. Are you not going to have a bit of a problem with engine cooling since the cooling fins are turned the wrong way now?

storminnorman07 · Mar 24, 2011

johnson05 said:
Beautiful work. Are you not going to have a bit of a problem with engine cooling since the cooling fins are turned the wrong way now?

i'm going to run a custom oil cooler. after trying one on my bros conversion build i'm pretty confident it will out cool the best cooler on the market for the minis. if i arill have a heat issue next in line to do once i figure out if this thing is going to live or not. Will be to make a custom billet cylinder w/ fins in the proper direction. i was going to now but i will have a good chunk of cash in the stock alone plus alot of machining time and i still do not know if the motor will hold up. but i really don't think i'll have a issue there are some china mills out there wiith fins running the wrong way that don't have heating issues.

storminnorman07 · Mar 25, 2011

progress is slow, i'm at a point that i absolutely hate doing! i hate prepping, blasting, polishing and cleaning. got the sub frame blasted, most of the frame blasted, got the rear rim apart blasted and labeled. got a great deal on these excel rims w/ talent hubs. bet you cant guess why? wouldn't be the horrible color combo a nice red with gold. when they are done they will be black rims and hubs w/ neon orange spokes like my frame.

dougtrip · Apr 4, 2011

you softened up a little huh, chad?

everything looks great!

can't wait to see the wheels done

storminnorman07 · Apr 4, 2011

dougtrip said:
you softened up a little huh, chad?

everything looks great!

can't wait to see the wheels done

lol yeah..... with the site change all my threads became viewable again had guys asking me about it figured i'd give it one more try. when you predicting your beast will be done? i just got some nice shiny takegawa stator and clutch covers for mine over the weekend

ill have to get some pics of them here soon.

storminnorman07 · Apr 6, 2011

got some new shiny parts

Mutant Motor Xr/klx

storminnorman07

manforrilla

storminnorman07

storminnorman07

storminnorman07

storminnorman07

AngryDirtbikers17

50rider340

507 brett

storminnorman07

skipbuysparts

Adam z50+R

Mx353

storminnorman07

johnson05

storminnorman07

storminnorman07

dougtrip

storminnorman07

storminnorman07

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