KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

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KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Tue May 10, 2016 11:20 pm

We received a bottom end from Scot for a rebuild.
The bike was purchased, not running a while back for a real steal of a price..
When we got it, I looked it over.
The cases were good, the crank looked pretty good so I thought this will finally be an easy one...
WRONG!!!
But before I get into that, I already had a KX500 crank on hand and ready to go... Balanced and polished with a Wossner rod...
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 102.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 102.JPG (105.59 KiB) Viewed 1796 times
And, I had our basic parts list on order with our local Kawasaki dealer..
kx500 basic parts list 101.JPG
kx500 basic parts list 101.JPG (164.42 KiB) Viewed 1796 times
kx500 basic parts list 102.JPG
kx500 basic parts list 102.JPG (97.98 KiB) Viewed 1796 times
Further, the Cometic gaskets and a few other parts came in quick...
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 101.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 101.JPG (168.72 KiB) Viewed 1796 times
If bikes are for kids I'll never grow up.

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Tue May 10, 2016 11:25 pm

When I opened the engine I saw that it was the best packaging job I had ever seen.
We do a pretty good job but this was awesome..
Unfortunately my cel phone broke and I couldn't take any pics...

Next I washed up the engine, don't want any extra debris getting into the engine..

Then I started on disassembly..

The flywheel had some unexpected damage..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 103.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 103.JPG (156.25 KiB) Viewed 1795 times
I have never seen one quite like that before..

Next I noticed that the clutch washer was really worn..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 104.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 104.JPG (133.45 KiB) Viewed 1795 times
Something was definitely up on this engine..
If bikes are for kids I'll never grow up.

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Wed May 11, 2016 12:35 am

Needless to say, we will be checking the ohm specs on this before it ever goes back into the engine...
There will also be a bit of clean up involved :lol:
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 105.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 105.JPG (78.25 KiB) Viewed 1782 times
Man, even the shift shaft spring is worn out :?:
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 106.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 106.JPG (90.58 KiB) Viewed 1782 times
All but three gears are junk... Both shafts are also done for :x
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 107.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 107.JPG (55.32 KiB) Viewed 1782 times
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 108.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 108.JPG (72.89 KiB) Viewed 1782 times
If bikes are for kids I'll never grow up.

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Wed May 11, 2016 12:43 am

Now you might be saying... Wait a minute, can't you get the gear dogs undercut?

Normally yes, however, the splines that the gears attach to the shafts on are worn out.
And the snap rings that hold the gears in their relative positions are completely wallered out....
Definitely something bad happened here..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 109.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 109.JPG (59.55 KiB) Viewed 1780 times
Then we discovered the problem...
Here is another case out of my top secret stash..
See the steel insert where the output trans shaft goes?
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 110.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 110.JPG (137.24 KiB) Viewed 1780 times
This engine had no insert..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 111.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 111.JPG (126.15 KiB) Viewed 1780 times
That means that the output shaft was just flopping around in there...
It's a wonder the engine did not grenade... :o
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 112.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 112.JPG (63.92 KiB) Viewed 1780 times
If bikes are for kids I'll never grow up.

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Wed May 11, 2016 12:50 am

The cases and clutch cover were warped pretty bad.
We had to spend some time on the granite surface plate before we could even lap..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 113.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 113.JPG (125.42 KiB) Viewed 1779 times
In all fairness, someone had welded the clutch cover fairly extensively..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 114.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 114.JPG (116.52 KiB) Viewed 1779 times
Once that was done Jason mixed up some Timesaver, 100 grit (Very fine) and started lapping the cases to insure a positive fit with no air leaks..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 115.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 115.JPG (132.47 KiB) Viewed 1779 times
Timesaver is so amazing... I thank Motorrad every time I use this stuff..
Bolt one case to the table so it doesn't walk around on you and go to town
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 116.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 116.JPG (122.39 KiB) Viewed 1779 times
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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Wed May 11, 2016 12:53 am

Back and forth, side to side, swirl and swirly.. Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat.. ect...
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 116.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 116.JPG (122.39 KiB) Viewed 1778 times
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 117.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 117.JPG (113.51 KiB) Viewed 1778 times
Jason even lapped the clutch cover 8-)
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 118.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 118.JPG (135.79 KiB) Viewed 1778 times
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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Wed May 11, 2016 12:57 am

Jason on the Vapor Blaster..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 119.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 119.JPG (149.11 KiB) Viewed 1777 times
Then into the Ultrasonic cleaner
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 120.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 120.JPG (106.32 KiB) Viewed 1777 times
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 121.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 121.JPG (121.01 KiB) Viewed 1777 times
If bikes are for kids I'll never grow up.

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Wed May 11, 2016 12:59 am

The results are amazing..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 122.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 122.JPG (95.87 KiB) Viewed 1776 times
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 123.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 123.JPG (105.15 KiB) Viewed 1776 times
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 124.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 124.JPG (99.42 KiB) Viewed 1776 times
If bikes are for kids I'll never grow up.

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Wed May 11, 2016 2:00 am

New parts..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 125.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 125.JPG (90.59 KiB) Viewed 1774 times
More new parts..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 126.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 126.JPG (110.36 KiB) Viewed 1774 times
Waiting... waiting...
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 127.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 127.JPG (108.92 KiB) Viewed 1774 times
If bikes are for kids I'll never grow up.

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE

Post by Sandblaster » Wed May 11, 2016 2:00 am

Ready for bearings and seals..
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 128.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 128.JPG (120.64 KiB) Viewed 1773 times
Hot!!!
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 129.JPG
JT ENGINE WORKS AND OEM-CYCLE KX500 BOTTOM END REBUILD 129.JPG (104.71 KiB) Viewed 1773 times
If bikes are for kids I'll never grow up.

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