Topic: 540v kawi?

[Johnson Mowersports]

No its stock ungoverned class prepared chassis with stock engines can have airfilter and exhaust and I had both Meatloaf I run 6 on engine to 2 1/2 on transaxle have a flipped spicer 6 speed and I run it in 5th gear Final ratio is like 5.5 or 6:1 doesn't bogg in the turn and pulls hard all the way through the straights

[more4les]

Ok. It's been a while but I'm still waiting on a ring gear....should be here today. In the meantime I stumbled onto a combo....460 piston in a 540. Need to bushing the rod (I'm going to use the 460 pin). Will be ready in a few weeks (cam isn't done yet). The ring gear on the Kawi is much coarser than the Intek ring i was going to try and didn't even attempt to engage the starter and take a chance on ruining the ring gear.

Lester

[Caudy155]

The 460s are awesome little engines too... I had one I got from burwell on here and it hadn't ran in prolly 5 years and I took the stock flywheel off but the arc on with a briggs coil and played with the low speed jet and built a healthy exhaust for it... ungoverned it would run all day with mod xrs... ran a feature race just playin around with them and ended up second... out of 5 I believe and I was about 2 feet from the winners front tires when we went across the finish... didn't think that was too bad for a stock 12.5 flatty with a billet wheel... couldn't imagine a 17 with a billet wheel...

[GRUBDIGGER]

Ok. It's been a while but I'm still waiting on a ring gear....should be here today. In the meantime I stumbled onto a combo....460 piston in a 540. Need to bushing the rod (I'm going to use the 460 pin). Will be ready in a few weeks (cam isn't done yet). The ring gear on the Kawi is much coarser than the Intek ring i was going to try and didn't even attempt to engage the starter and take a chance on ruining the ring gear.

Lester

I BELEIVE THE 420 AND THE 540 ARE THE SAME PISTON. LONGER STROKE ON THE 540.

[more4les]

I BELEIVE THE 420 AND THE 540 ARE THE SAME PISTON. LONGER STROKE ON THE 540.

And so is the 460 (89MM). It has more compression height and is a slightly domed piston vs the big dished piston of the 540. I will be milling and reshaping the top of a 460 piston for the 540.

Lester

[GRUBDIGGER]

GOOD TO KNOW FOR THE FUTURE.

[Flipper]

And so is the 460 (89MM). It has more compression height and is a slightly domed piston vs the big dished piston of the 540. I will be milling and reshaping the top of a 460 piston for the 540.

Lester

Great minds think alike! LOL
that's where I am at too, experimenting with a 460 piston,
I'm working on a balanced crank without using the factory counterbalance.....
Been talking to Performance about a cam and Isky.
Keep me posted on your flywheel, and if you would consider making more/selling them.
I think the stock rod is pretty beefy and a billet is not needed.
With the long stroke, My guess is this will only be around a 6500rpm engine, but with tons of grunt.

Both the 420 & 540 stock pistons are "Dished" or "cupped", and share the same bore, (as Grub said, the 540 just has a longer stroke)

[more4les]

I have Tim Isky building the cam. Not going too radical (unlike what I did for the 460 lol). I'm building an oil lite brass bushing for the the stock rod so I can use the 460 pin. I'm going to balance the crank and remove the weights. I have my 460 crank on the balancer now and I'm surprised how little added weight will be needed.

Lester

[Flipper]

I think most Kawi's come "pre balanced" from the factory. Huffy44 balanced my 460 crank, he said he went thru a few bits on the lathe, where he normally only uses one. Pretty tough steel. He used the Briggs weights on it.
Very interested to see how yours comes out!
I'll investigate Isky on the cam with more intent. They did one for one of my Kawi Twins, it's pretty violent.

[more4les]

I used the lathe to clearance the crank for the cam lobes and yea pretty hard...I'd dare say a forged crank, if not sure looks like one. I used C2 carbide bits and they grunted .

Lester

[Rooster]

When you get tires of buying those C2 bits...get an inserted tool! LOL
They are an investment, but if you get the right tool they cut better and when you start buying inserts you get 4 or 6 cutting corners for $15-$20!

SECO has an MP2500 grade...and I think a newer one now, that is great at cutting harder stuff. they are what I use on titanium valves.

[more4les]

These are the insert type but all I bought was C2 inserts. Going to get C5 soon.

Lester

[more4les]

I went through an ordeal with my ring gear. I decided to hand it off to a friend who does machine work for a living (old school machine shop - no cnc stuff at all) and for what ever reason refused to preheat the ring gear (as I recommended) and tried to cold press it on with 2 thousandth press. It simply "cut" the .002" off and well was not a tight fit. He was mulling what to do so I kinda got a bit mad and said you didn't listen so now weld it back up, re-cut it and do it again...this time HEAT THE RING GEAR!!!!! He did and it's done. Not pretty but done (and true). Parts for these things take forever to get. Hoping the new piston (FB460V - 89.25mm) is here before the weekend.

Lester

[rotten ron]

It doesn't take much heat to expand a ring gear ,then it just falls on

[Flipper]

I went through an ordeal with my ring gear. I decided to hand it off to a friend who does machine work for a living (old school machine shop - no cnc stuff at all) and for what ever reason refused to preheat the ring gear (as I recommended) and tried to cold press it on with 2 thousandth press. It simply "cut" the .002" off and well was not a tight fit. He was mulling what to do so I kinda got a bit mad and said you didn't listen so now weld it back up, re-cut it and do it again...this time HEAT THE RING GEAR!!!!! He did and it's done. Not pretty but done (and true). Parts for these things take forever to get. Hoping the new piston (FB460V - 89.25mm) is here before the weekend.

Lester

If my memory serves me correctly, I think Jason M did that on the Kawi Twins Billet flywheel. Heated them up for removal and installation of the ring gear. Never had an issue with any of mine, love the steel ring gear.

Are you going to use the newer K series plastic flywheel fan on top?

So, Lester, since this is experimental Billet flywheel number one for the FC540v, what do you think you have invested so far?
(if you feel that's an inappropriate question, PM me)

My Billet rod for the 460 shocked and stunned me with the overall cost….not sure if I would do that again.
(Billet Flywheel is needed, not so much a rod, as, the stock Kawi's seem to hold together quite well)