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

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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...

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And, I had our basic parts list on order with our local Kawasaki dealer..

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Further, the Cometic gaskets and a few other parts came in quick...

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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..

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I have never seen one quite like that before..

Next I noticed that the clutch washer was really worn..

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Something was definitely up on this engine..

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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

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Man, even the shift shaft spring is worn out

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All but three gears are junk... Both shafts are also done for

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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..

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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?

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This engine had no insert..

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That means that the output shaft was just flopping around in there...
It's a wonder the engine did not grenade...

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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..

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In all fairness, someone had welded the clutch cover fairly extensively..

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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..

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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

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Back and forth, side to side, swirl and swirly.. Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat.. ect...

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Jason even lapped the clutch cover

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Jason on the Vapor Blaster..

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Then into the Ultrasonic cleaner

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The results are amazing..

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New parts..

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More new parts..

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Waiting... waiting...

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Ready for bearings and seals..

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Hot!!!

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