Gsxr 600 engine for my KLT 250

[MidwestATC]

Sooooo I seem to be the kinda guy that has to many irons in the fire lol. My little brothers girlfriend just got a new 750 engine for her 93 gsxr600. Well needless to say ive been itching to make a rear suspension for the klt and now looks like I'll be doing it and stretching the frame 4" to fit the gsxr engine. Anyone have any words of wisdom?

[New2Tri-Z]

Anyone have any words of wisdom?

Yes get a bible and a good helmet, your going to need it :crazy:

[Ghostv2]

You might as well replace the whole front end too. That stock front suspension won't help much with that kinda power plant.

[jb2wheels]

Leave it hard tail - like the old school RD trikes!

Is that GSXR engine water cooled? Just curious - I can't remember when they switched.

[kaymo]

get some good insurance. health and life.

[MidwestATC]

Leave it hard tail - like the old school RD trikes!

Is that GSXR engine water cooled? Just curious - I can't remember when they switched.

Water cooled. And I still can't figure out where the rad will sit. Maybe on the front cargo rack. I was hoping to find a kz650 engine sometime later to put in it but this one was free so here it goes. What's the bible for a tire chock? Insurance hahahahahahaha I'm a cook at Denny's. Good joke though. Lol and the front end I already replaced the front springs with a set of Honda rebel shocks a while ago and that made a world of a difference.

[toki]

pics or it didnt happen

[atc007]

Water cooled. And I still can't figure out where the rad will sit. Maybe on the front cargo rack. I was hoping to find a kz650 engine sometime later to put in it but this one was free so here it goes. What's the bible for a tire chock? Insurance hahahahahahaha I'm a cook at Denny's. Good joke though. Lol and the front end I already replaced the front springs with a set of Honda rebel shocks a while ago and that made a world of a difference.
I'd say you're set since you have a set of Rebel shocks on it already.

[MidwestATC]

pics or it didnt happen

Lol this always happens.. Which is why I take pics of the things I work on lol
http://i12.photobucket.com/albums/a211/midwestmk2/0B309D85-D5C7-42F9-93FB-02209C3B54A0.jpg
http://i12.photobucket.com/albums/a211/midwestmk2/67456DD5-8F9E-4389-A5FA-202B89D91C3F.jpg
http://i12.photobucket.com/albums/a211/midwestmk2/4C4F5B80-57C4-4CCE-B39B-8DEC36EB7039.jpg
http://i12.photobucket.com/albums/a211/midwestmk2/07C0ACDA-0E2A-40B3-BDB2-DD52EA132B73.jpg
There is a jig on the other side of the garage to get it all strait. I need to get the tubing and gussets made for the motor mounts and frame stretch then I'll start on fabbing a swinger. The engine needs to be set back quite a bit more this was just to help everyone's visual aid. I have a rear shock from a Honda foretrax for the rear but if it's to stiff or not enough travel I can swap to the one from my old Yamaha 125 mono cross. I'll probably be using the later of the 2 though.

[MidwestATC]

Here you can see the original wimpy springs(not shocks). I can compress these by hand almost 2". In the other pics you can tell clearly how many more coils on the springs and they are actually shocks. The front use to buck going down the road at speed but after the shock swap it rides nice and smooth no bucking. The rebel shocks are on the lowest and softest preload setting. I can take a side by side if anyone would like?
http://i12.photobucket.com/albums/a211/midwestmk2/27D77452-8D1C-4064-A5DE-090057373C5B.jpg

[toki]

Lol this always happens.. Which is why I take pics of the things I work on lol

:o oooh touche! nicely done lol! gonna have to get creative with the radiator... front rack? under seat/above rear axle maybe? more progress and more pics! this is gonna be nuts! I would keep the plastics and everything the same... rat rod death machine from hell lol.

p.s. i have a kz650 just chillin in my garage :P but i live in wisconsin.

[Ghostv2]

Seeing it all stretched out got me thinking, drag bike?

[MidwestATC]

I was going to lay a small rad on the front or I also have a set of side mount rads from a water cooled 2 stroke dirt bike as well. It's going to be a lot of trial and error. The 600 engine is also 2" taller and I'll have to raise the seat height slightly. I'm going to do my best to keep the stock plastics. Stock air box is a no go and I will be making a log style plenum to replace it. The engine also has a 520 chain conversion which make the swap easier and the rear sprockets on both the bike and trike are the same tooth count. Which just so happens to be 10 more than stock lol. The tire heights are the same as well so it should be easily able to run to 120mph and still have the low gear grunt to get you over obsticales or just blow the tires right off at will lol. This is going to be a long project but I will keep you all updated with pics.

[jakep53]

HOLY trailprotrailprotrailprotrailpro 120mph hang on!!!

[DohcBikes]

So, you cut a klt250 in half, and set a motor in between the halves. Not bad for a short order cook. Only about 3 grand away from a decent rider that has even a hint of safety in mind.

A for Ambition, but if that thing ever runs and drives I'll eat my hat. I beg you to prove me wrong.

[MidwestATC]

Sounds good sir lol. I just got the go ahead to dismantle the motorcycle the engine came from so I can use the radiator,header and carbs before I build the subframe to house it all. After more measureing and measureing I figured I can still fit the rad up front and my Honda 200s gas tank seams to fill the spot between the seat and bars just fine. Lol. Here is another mock up photo of all the parts. I hade to flip the stock rear frame rails to use as my swing arm. Going to pick up some 3/4" Hiem joints for the swinger mounts. I've decided to use the shock from my old dirt bike. The top one is the foretrax shock compared to the dirtbike one. Plus the adjustability of it makes it a no brainer. I may only be a short order cook but I've been chopping things up and creating crazy contraptions all my life.
Here is the shocks.
http://i12.photobucket.com/albums/a211/midwestmk2/E3ED457A-D1F8-4FF7-A76C-B1E398BE66ED.jpg
And here is a pic of it all just mocked up.
http://i12.photobucket.com/albums/a211/midwestmk2/8A8F267A-10A8-4BE8-8AE9-7DF6ECD53A33.jpg

[DohcBikes]

If it ends up with the dimensions and stance of the mockup photo it will be very unsafe. Prepare for a gearing nightmare with the top end biased inline.

Watching and shaking my head so far.... keep it going.

[DohcBikes]

You might as well replace the whole front end too. That stock front suspension won't help much with that kinda power plant.

Disagree on this... the front end was built to take abuse and some jumping with adults on it. Also, the leading link suspension will help when tuning the handling.

[Ghostv2]

Disagree on this... the front end was built to take abuse and some jumping with adults on it. Also, the leading link suspension will help when tuning the handling.
Just shoot down everyone's ideas why don't ya.

[MidwestATC]

The demensions of the mock up are pretty close to that of a 250x. The wheelbase is only 2.5" longer and it also sits 2.5" taller as well to make up for the break over angle. The swinger is tilted just a few more degrees down farther than the gsxr swinger. As for gearing the stock sprocket on the Klt is the same tooth count as the One that was on the gsxr but it is also 8 teeth more than the stock one. We geared it down to be a drag/stunt bike. So it revs up high always anyway from the low gearing. That's also why it got a 750 engine in it now lol. Plus safety is relative. You can give some idiots the safest thing in the world and somehow find away to maim or kill 4 people with it. I know I'll have a good healthy dose of respect for this toy for sure. It's got a whole new learning curve.

[DohcBikes]

Just shoot down everyone's ideas why don't ya.

To me, it's kind of like fishing with a net, instead of a pole. My perception of a discussion forum is that all opinions are shared, then discussed. It doesn't have to be Guiding Light or Dallas up in here. Just being honest about what I think of the project.

All while keeping in mind that major motivation can be obtained from others doubts. My word is certainly not the last one.

[ktmcrasher]

do you think you can build it tough enough that it won't self destruct? 100+ bhp in that old frame should be testing.

good luck with the build, great project.

[Ghostv2]

To me, it's kind of like fishing with a net, instead of a pole. My perception of a discussion forum is that all opinions are shared, then discussed. It doesn't have to be Guiding Light or Dallas up in here. Just being honest about what I think of the project.

All while keeping in mind that major motivation can be obtained from others doubts. My word is certainly not the last one.
I was just joking.

But I know how projects go for me when doing basic rebuilds to partial restoration which is really just cleaning up and painting parts like frames. I get all excited and filled with ambition, take it apart in one day, spend 3 months putting it all back together. And that's a good project lol.

I'd like to see video of it in action, so hopefully he has more motivation than me.

[MidwestATC]

DOHC is correct doubt does set fires under people's asses lol. KTM the frame was plenty strong enough before I cut it up but I'm one of those guys who will gusset every weld or connection no matter how minuscule it seems lol. I have quite abit of motivation when it comes to building toys. My equalizer is the money it takes to build them but I usually make up for it with ingenuity or recycling of old pieces into what I need. Don't get me wrong there are a lot of things you just can't backyard fab. I finished off my GF's bike into a rolling chassis about 2 months after getting it. Now it sits wait for a new engine but it's just the motor rebuild for it is going to cost as much as the tranny in my truck. Plus the colder it gets the more I'm going to need the truck. I've tried to ride my motorcycle in the snow and that didn't work out to well( never made it out of my drive) lol. This build only involves money when it comes to the steel and welding wire to build it besides the small things that need to be bought. Also the header and the oil pan are going to be swapped for ones from a suzuki rf 900. The oil pan is a lot shorter and the header completely covers the bottom of it and acts as a skid plate.

[250rRoostmaster]

So how's this crazy project coming along?

[nstyle73]

I think the best part was the little cart that wheeled the engine around on. I need one of those. I have a KLT, and although my opinion is cutting it apart would make it useful, I still ask WHY?

[onformula1]

Any updates?

Have you thought about adding a parachute? Top fuel style.

Those old brakes were not great on a 200.

[El Camexican]

Any updates?

Have you thought about adding a parachute? Top fuel style.

Those old brakes were not great on a 200.

He's gotta get it to move before there's a need to stop it:lol:

[MidwestATC]

Update.. Well got a new job that leaves me no free time and moved. Now I have no garage for my toys and they are in storage for now at my moms. Just found out that I'm going to be a daddy this week and now things just got real and projects will be a long term goal for now. Still plan on building this thing but it's gonna take a lot longer than I had previously assumed. Why cut it up. Why not the engine needs a rebuild and going into a go cart my friend is working on. Nothing else to use the gsxr engine as well lol. Parachute..? Nah if I'm going that fast I'd rather the chute be on me lol.

[onformula1]

Update.. Well got a new job that leaves me no free time and moved. Now I have no garage for my toys and they are in storage for now at my moms. Just found out that I'm going to be a daddy this week and now things just got real and projects will be a long term goal for now. Still plan on building this thing but it's gonna take a lot longer than I had previously assumed. Why cut it up. Why not the engine needs a rebuild and going into a go cart my friend is working on. Nothing else to use the gsxr engine as well lol. Parachute..? Nah if I'm going that fast I'd rather the chute be on me lol.

Congrats! Daddy.
Keep us posted.

[MidwestATC]

Update things kind of just fell apart the last few months. Mom is selling her house so the toys have to find a new home. I had to sell the gsxr motor to repair my tranny in the truck. I'm really upset about this I was soooooo looking forward to getting to finish this thing. Looks like I have fallen victim to the look what I'm gonna do, oh wait never mind bug. Lol Hopefully one day it may start agian.

[thehorse13]

Someone must have been praying for you. If that thing ever ran, you would likely be paying for funeral services instead of a truck transmission.