Tim's 98 KX500 engine build

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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 6957 times

Nice pretty blue hose

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

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Everything seemed to be ok until we heard this

https://youtu.be/4Zw9urYXxw0

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

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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

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

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More case mods...

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Jason hard at work like a surgeon with dirty finger nails

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Nice work Jason...

www.oem-cycle.com kx500 1998 full rebuild 106.JPG (55.28 KiB) Viewed 6920 times

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Almost ready for plating..

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OEM-CYCLE.COM kx500 cylinder almost ready for plating 102.JPG (56.09 KiB) Viewed 6916 times

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

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

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www.oem-cycle.com kx500 1998 full rebuild 108.JPG (55.8 KiB) Viewed 6687 times

www.oem-cycle.com kx500 1998 full rebuild 107.JPG (60.76 KiB) Viewed 6687 times

www.oem-cycle.com kx500 1998 full rebuild 111.JPG (61.25 KiB) Viewed 6687 times

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

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

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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 6619 times