What are the biggest valves available for a 2003 650, what is their cost and availability (time)?
As big as you like. Special order only with a delivery time of roughly 3- 4 weeks.
36 Intake / 31 Exhaust, delivery time 3-5 days.
37 intake / 32 Exhaust, delivery time most often 1- 2 weeks.
Cost: $400.00 US plus S/H
What modifications are need to the head and seats to allow the bigger valves to be used?
OEM seats will suffice through 37 mm Intake and 32 mm Exhaust.
The 37 mm Intake is pushing the limit of the OEM Intake seat in particularly on pre 2000 engines.
With replacement seats and offset guides 40 plus is possible.
As you know I am now building a 750cc Husaberg motor based on the piston in my gallery and a 4mm stroked '03 crank. This motor doesn't need to be rideable - it needs to make as much power as possible every were but favoring top end. It is to be used in a motocross sidecar were the throttle is either on or off. It is pulling 165kg bike + 2 riders so the weight tends to tame the power to a usable limit.
What mods (big valves, cams etc.....) do you think would help with this end goal?
In sequential order:
Longer duration / increased overlap camshaft with matching intake and exhaust resonance.
Tuned, low restriction intake and exhaust plumbing. (see above)
Increased exhaust valve size with matching port work.
Increased intake valve size with matching port work.
properly tuned 41 - 44 mm smoothbore carburetor.
proper ignition timing (ie most likely a slight reduction in WOT advance).
Do you forsee any weak spots down stream of the crank? The balencer is going.
OEM Cylindrical main bearings are quite strong albeit very sensitive to proper axial alignment and running fit.
On tarmac and without the benefit of a cush drive the gearbox can prove troublesome, however, where some wheel slip is available as in off-road you should have little if even anything to worry about.
Happy new year.
Best Regards
Ben Ballard
JBSracing