Tim's 98 KX500 engine build

[Sandblaster]

We have a 98 KX500 engine in for a full rebuild.
The very first thing we did was to take it outside and wash it...
Nothing worse then working on a dirty engine and contaminating everything as you open her up..

www.oem-cycle.com kx500 1998 full rebuild 101.JPG (78.21 KiB) Viewed 7938 times

Nice pretty blue hose

www.oem-cycle.com kx500 1998 full rebuild 102.JPG (75.63 KiB) Viewed 7938 times

Doah.... happens on almost every one of these...

www.oem-cycle.com kx500 1998 full rebuild 103.JPG (30.24 KiB) Viewed 7938 times

[Sandblaster]

Everything seemed to be ok until we heard this

https://youtu.be/4Zw9urYXxw0

[Sandblaster]

Tim, one of these bad boys is for you...

www.oem-cycle.com tims kx500 build 106.jpg (350.23 KiB) Viewed 7918 times

[Sandblaster]

We got a bit of lapping done today.
These cases were about the worst we have seen.
Spent almost a hour to get them perfect

www.oem-cycle.com tims kx500 build 107.jpg (432.11 KiB) Viewed 7905 times

The head and cylinder were nice to begin with.
They are epic now

www.oem-cycle.com tims kx500 build 108.jpg (408.97 KiB) Viewed 7905 times

[Sandblaster]

More case mods...

www.oem-cycle.com kx500 1998 full rebuild 104.JPG (81.07 KiB) Viewed 7901 times

Jason hard at work like a surgeon with dirty finger nails

www.oem-cycle.com kx500 1998 full rebuild 105.JPG (44.33 KiB) Viewed 7901 times

Nice work Jason...

www.oem-cycle.com kx500 1998 full rebuild 106.JPG (55.28 KiB) Viewed 7901 times

[Sandblaster]

Almost ready for plating..

OEM-CYCLE.COM kx500 cylinder almost ready for plating 101.JPG (66.48 KiB) Viewed 7897 times

OEM-CYCLE.COM kx500 cylinder almost ready for plating 102.JPG (56.09 KiB) Viewed 7897 times

[Sandblaster]

Just got the crank back from the rebuilder...
Of course it's balanced

www.oem-cycle.com tims kx500 build 112.jpg (138.71 KiB) Viewed 7858 times

www.oem-cycle.com tims kx500 build 111.jpg (168.55 KiB) Viewed 7858 times

www.oem-cycle.com tims kx500 build 110.jpg (226.41 KiB) Viewed 7858 times

www.oem-cycle.com tims kx500 build 109.jpg (143.58 KiB) Viewed 7858 times

[Sandblaster]

Received the cylinder back from Millennium Tech...
Beautiful.....
So, Jason finished up porting and polishing...

www.oem-cycle.com kx500 1998 full rebuild 110.JPG (66.58 KiB) Viewed 7668 times

www.oem-cycle.com kx500 1998 full rebuild 109.JPG (63.69 KiB) Viewed 7668 times

www.oem-cycle.com kx500 1998 full rebuild 108.JPG (55.8 KiB) Viewed 7668 times

www.oem-cycle.com kx500 1998 full rebuild 107.JPG (60.76 KiB) Viewed 7668 times

www.oem-cycle.com kx500 1998 full rebuild 111.JPG (61.25 KiB) Viewed 7668 times

[Sandblaster]

I just got a call today.... All the gears are in!!!

[Sandblaster]

Fresh out of the oven.... Mmmmmmm.... Love that smell

www.oem-cycle.com kx500 1998 full rebuild 112.JPG (73.35 KiB) Viewed 7600 times

Replaced the shift forks, 6 of the gears including 3rd and 4th input and output.

www.oem-cycle.com kx500 1998 full rebuild 113.JPG (136.34 KiB) Viewed 7600 times