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August 9th, 2014, 02:58 AM   #91
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I Ride: 2008 700FK, 2002 628FST
78mm KTM crank

1700 usd comes with carillo rod
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August 9th, 2014, 03:12 PM   #92
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August 22nd, 2014, 07:17 PM   #93
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I Ride: fe450 150exc
2008 fe450 crank

I just tore my 450 apart to remove the counter balancer and hopefully lighten and change the balance factor. I calculated the stock balance factor is .43 has anyone checked a 450 to confirm this is close? anyway, not knowing where to start, I am going to shot for 62% unless someone has a better idea.... I am also grinding/turning down the od of the crank to lighten the flywheel effect. The crank cheeks look like they were made for a 650! Just trying to make it feel like a ktm 350. Also the crank bearings were perfect, over 200 hours on this motor. Stock skf bearings...I didn't rev it much because of the vibration.
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August 23rd, 2014, 07:32 PM   #94
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sounds good, the 628 has around 9mm between crank OD and the outer edge of the big end pin

the ktm RFS crank modifiers reckon 6mm is the limit with a 525/570 strokers, seems a bit too flimsy when you look at the whole setup

i guess around 8 mm would be pretty safe on the 450
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August 24th, 2014, 05:49 PM   #95
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Your looking at 15 hours of work.....

The first shows the difference in diameter I removed. The second is the final product porkchopped to get .62 balance factor. The crank is now 2 pounds lighter. I'll post the results after i ride it. I'm still waiting on a 20mm wide bearing for the pto side.

My piston weights 400 grams with pin and clips. Seems odd it would be more than the 650 piston. Not sure if its oem, it says 810-100 8156f group 1?
Attached Thumbnails
Balancing an 80mm 650 crank-img_20140823_110120.jpg   Balancing an 80mm 650 crank-img_20140824_192115.jpg  
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Last edited by eric82930; August 24th, 2014 at 05:51 PM.
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August 24th, 2014, 08:48 PM   #96
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very nice work eric thanks for posting the pics,

now about the same weight as mine

wossner piston data here

http://gyucn.dezxt.servertrust.com/v...ns_catalog.pdf

650 piston is similar height same diam but dished -10.5cc, 450 is listed with +9cc to get the high CR which should come out at about 50 gm heavier

Last edited by bushmechanic; August 25th, 2014 at 09:22 PM.
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September 2nd, 2014, 07:38 AM   #97
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fe450 counter balancer removal final results

I rode the 450 this weekend. It does have more vibration at idle and mid but no more rattle and top end rpm feels way smoother than before. The motor seems quiet,tight and has a new bike feeling. It feels more powerful and revs much quicker even tho I lowered the compression by removing .040" off the top of the piston. It will wheelie easier at any rpm. Stalling is not a problem, still way better than any mx450. The cam makes theese motors never say die. I swear the bike feels 30 lbs lighter. I would not do this if you dual sport a lot. I did about 20 miles of dirt road and my butt could feel the vibs but not too bad in the bars. On trail you don't notice unless you purposefully think about it....

My 2 buddies swapped with me for a few miles.
#1 had a kx450-I told him BEFORE he rode it to see if he thought it had too much vibration. When he got off it, he said he forgot to check the vibration but loved the smooth power and the suspension. I guess that means he didn't notice the vibration at all.....I rode the kx and it had zero vibs but it has a balancer.The kx powerband makes it a mean animal that would stall in a millisecond...Power was a bit more over all than the berg but who cares when trail riding....It was also way too loud, hard to start, crappy clutch. Very fast and stable until it wears you out.

#2 had a 150xc-He told me he could feel the vibs but only when he was purposely thinking about it. But he called it a cheater bike. I rode his 150 and it vibed too just at a higher frequency.

Looking back, I think the sound of the counter balancer rattle was a big issue for me. I didn't think it was that bad at the time, but I remember times even at low rpm road riding in 6th gear, I would down shift and ride in 5th just to get rid of the rattle it had at a certain rpm. And In my memory it just seemed sluggish even though it was plenty fast it had a lazy feel too it before.
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Last edited by eric82930; September 2nd, 2014 at 07:42 AM.
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September 2nd, 2014, 11:27 AM   #98
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How'd you do that?
You put the whole crankshaft to the lathe?

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September 10th, 2014, 03:55 AM   #99
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Originally Posted by bushmechanic View Post
78mm KTM crank

1700 usd comes with carillo rod
If you sweet talk crankworks (who makes the TR crank) you might be able to get one a bit cheaper. I paid $350 per crank wheel for the (non TR) billet version (same base Travis is using for his ultralight crank)


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September 10th, 2014, 04:28 AM   #100
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nice Crank Jar, thanks for the tip

what did you use for the big end pin / rod ?
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