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Kawasaki EX500 2 stroke
http://kawi2strokes.com/forum/viewtopic.php?f=21&t=14136		 Page 4 of 5
Author:  DGA [ Thu Jun 11, 2020 12:27 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
Thanks guys. Latest work on it, increased the front sprocket from 16 to 17, it just pulls much better than the stock motor from low revs, 1500 rpm it's quite tractable and smooth, even after I changed the exhaust valves to 82 deg ATC opening. Reed intake spreads the powerband out very wide. I am low on alternator output, running voltage is only 11.8 volts, with the head light unplugged. I used a Mercruiser EFI big block fuel pump, was one of the few external inline small pumps I could find, and it's too much current draw, so am working on adapting a smaller Delco in tank pump to external use with end adapters.
Author:  DGA [ Wed Jan 20, 2021 12:04 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
So, partly because no two stroke ever has a turbo, all diesel two strokes have a blower, because you can't start them without boost, and you will never get boost before the engine runs, I wanted to add a turbo to this EX500 two stroke design. It has a drawback as is with the fact that the suction in is lower volume than the swept volume of the cylinders. So a turbo will take care of that nicely. Typical two strokes can never use turbos because the heat on the piston exhaust face finishes does them in quickly. I already have all the EFI in place so can easily change the fuelling for boost, carbs and boost aren't a good combination. Am adding an air to air intercooler above and behind the throttle bodies, basically where the massive original airbox used to reside. Will add more pics as I get progress.
Author:  Jim [ Wed Jan 20, 2021 12:21 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
If you deliver this to the 2-stroke meet in May, I'll test it all week, free!
Author:  DGA [ Wed Jan 20, 2021 12:47 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
Jim wrote:
If you deliver this to the 2-stroke meet in May, I'll test it all week, free!

LOL I'm sure you would!
The turbo, is a VZ21, Chinese copy of an IHI RHB31, some rate it at 80 hp, others say 100 hp. I have ported it out a lot, so think it should flow enough to support 110 hp or so. Heat shielding is an issue, yes, that's the fuel rail behind the down pipe exhaust. Also has the rear valve exhausts coming from the rear of the head, still working on that part. The turbo fits nicely inside the lower chin cowl of the EX500. Now only needs one muffler, so I saved some weight from removal of that. Headers are 1", secondaries are 1.25" and the turbo tailpipe is 1.5", all 304 stainless.
Author:  Jim [ Wed Jan 20, 2021 12:59 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
I don't remember if you said already, but what's it look like for the overall weight compared to the stock EX500?
Author:  DGA [ Wed Jan 20, 2021 1:06 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
I have not done a weight, before and after check. The turbo is about 6 lbs, intercooler around 4 lbs, it will have carbon fiber tanks. Throttle bodies, ECU and harness weigh less than the two carbs they replaced. Have lost maybe 15 lbs from the stock exhaust, with it's huge twin mufflers. I would guess I'm up by 20 lbs over stock.
Author:  Jim [ Wed Jan 20, 2021 2:57 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
Not bad, thanks.
Author:  Ja-Moo [ Fri Jan 29, 2021 11:13 am ]
Post subject:  Re: Kawasaki EX500 2 stroke
Just very cool stuff...... :clap: :clap: :clap:
Author:  DGA [ Fri Feb 26, 2021 5:35 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
Got the intercooler done for this Kawasaki EX500 two stroke design. Weighs 4 lbs, not bad.
Author:  Jim [ Fri Feb 26, 2021 6:12 pm ]
Post subject:  Re: Kawasaki EX500 2 stroke
Very nice!
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