Sean Colliers KX500 Project "I was only going to inspect the top end"

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Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Mon Sep 26, 2016 12:27 am

This is the bike that Sean won the Two Stroke National Championship on at Glen Helen in 2015 on.
The tear down is being handled by Oscar.
All the notes and pics provided below are his.
This build is not really a build as much as it is a quick freshen up of the chassis and motor to keep it alive until we get Sean's new bike built.
Here is the beast...
SEAN COLLIERS KX500 TEAR DOWN 101.JPG
SEAN COLLIERS KX500 TEAR DOWN 101.JPG (80.82 KiB) Viewed 2621 times
Oscar didn't get too far into the tear down when he found the first issue.
Don't you just love it when you go to take a bolt out and it spins round and round and never comes out?
SEAN COLLIERS KX500 TEAR DOWN 102.JPG
SEAN COLLIERS KX500 TEAR DOWN 102.JPG (62.08 KiB) Viewed 2621 times
Someone hated on this air box... Man.. that's a lot of holes :shock:
SEAN COLLIERS KX500 TEAR DOWN 103.JPG
SEAN COLLIERS KX500 TEAR DOWN 103.JPG (108.49 KiB) Viewed 2621 times
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Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Mon Sep 26, 2016 12:31 am

Oh yeah, that needs a bit of work..
SEAN COLLIERS KX500 TEAR DOWN 104.JPG
SEAN COLLIERS KX500 TEAR DOWN 104.JPG (61.98 KiB) Viewed 2619 times
This is the world famous one off hand built muffler from FMF.
I know a few guys that would like to have one... Including me.
SEAN COLLIERS KX500 TEAR DOWN 105.JPG
SEAN COLLIERS KX500 TEAR DOWN 105.JPG (79.19 KiB) Viewed 2619 times
Broken motor mount?
No good, that will cause a lot of undue stress on the frame as well as a lot more chassis vibration.
SEAN COLLIERS KX500 TEAR DOWN 106.JPG
SEAN COLLIERS KX500 TEAR DOWN 106.JPG (65.37 KiB) Viewed 2619 times
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Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Mon Sep 26, 2016 12:36 am

Standard FMF Woods Gnarly pipe.
SEAN COLLIERS KX500 TEAR DOWN 107.JPG
SEAN COLLIERS KX500 TEAR DOWN 107.JPG (34.11 KiB) Viewed 2614 times
OUCH!!!! Someone get me the eye bleach, those welds are UGLY!!!! :lol:
SEAN COLLIERS KX500 TEAR DOWN 108.JPG
SEAN COLLIERS KX500 TEAR DOWN 108.JPG (65.98 KiB) Viewed 2614 times
NGK B8EVX Gapped at .024"
SEAN COLLIERS KX500 TEAR DOWN 109.JPG
SEAN COLLIERS KX500 TEAR DOWN 109.JPG (34.45 KiB) Viewed 2614 times
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Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Mon Sep 26, 2016 12:44 am

Bare bones stock 97-04 KX500 carburetor.
SEAN COLLIERS KX500 TEAR DOWN 110.JPG
SEAN COLLIERS KX500 TEAR DOWN 110.JPG (58.45 KiB) Viewed 2610 times
SEAN COLLIERS KX500 TEAR DOWN 113.JPG
SEAN COLLIERS KX500 TEAR DOWN 113.JPG (56.72 KiB) Viewed 2609 times
This rad stinks...
SEAN COLLIERS KX500 TEAR DOWN 111.JPG
SEAN COLLIERS KX500 TEAR DOWN 111.JPG (126.52 KiB) Viewed 2610 times
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Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Mon Sep 26, 2016 12:52 am

Oh man.... look at this clutch cable.
KX500 cables are notorious for being routed improperly and bent too hard at the steel sleeve causing a harder pull...
This one is beyond any of that...
SEAN COLLIERS KX500 TEAR DOWN 112.JPG
SEAN COLLIERS KX500 TEAR DOWN 112.JPG (35.46 KiB) Viewed 2607 times
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Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Mon Sep 26, 2016 3:38 am

There is something very fishy about that center valve..
SEAN COLLIERS KX500 TEAR DOWN 114.JPG
SEAN COLLIERS KX500 TEAR DOWN 114.JPG (85.92 KiB) Viewed 2604 times
Yep... It's busted..
SEAN COLLIERS KX500 TEAR DOWN 115.JPG
SEAN COLLIERS KX500 TEAR DOWN 115.JPG (45.73 KiB) Viewed 2604 times
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Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Mon Sep 26, 2016 3:39 am

Yeah, this frame has serious issues... And Sean was airing this thing out.... :o :shock: :o
SEAN COLLIERS KX500 TEAR DOWN 116.JPG
SEAN COLLIERS KX500 TEAR DOWN 116.JPG (59.39 KiB) Viewed 2603 times
SEAN COLLIERS KX500 TEAR DOWN 117.JPG
SEAN COLLIERS KX500 TEAR DOWN 117.JPG (71.38 KiB) Viewed 2603 times
SEAN COLLIERS KX500 TEAR DOWN 118.JPG
SEAN COLLIERS KX500 TEAR DOWN 118.JPG (32.19 KiB) Viewed 2603 times
I guess we need a new frame....
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Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Tue Sep 27, 2016 3:55 pm

Awwwww... What a little cutie..
KX GURU RACING SEAN COLLIER KX500 162.JPG
KX GURU RACING SEAN COLLIER KX500 162.JPG (80.53 KiB) Viewed 2598 times
KX GURU RACING SEAN COLLIER KX500 163.JPG
KX GURU RACING SEAN COLLIER KX500 163.JPG (74.25 KiB) Viewed 2598 times
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Wed Sep 28, 2016 2:44 am

Oscar is discovering how difficult it can be to remove even slightly rusted parts :lol:
SEAN COLLIERS KX500 TEAR DOWN 119.JPG
SEAN COLLIERS KX500 TEAR DOWN 119.JPG (73.9 KiB) Viewed 2581 times
SEAN COLLIERS KX500 TEAR DOWN 120.JPG
SEAN COLLIERS KX500 TEAR DOWN 120.JPG (47.88 KiB) Viewed 2581 times
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by USMC 500 » Wed Sep 28, 2016 4:39 am

OK, so what was supposed to be just an inspection for the head and jug for specs and work performed by the previous builder turned into a full blown quality budget rebuild. As I tore down the bike to pull the engine out I began to find issue after issue, basically a can of worms, Pandora's box and any other analogy you care to use. All the photos above just tell a small story of the actual tear down but in the end it was decided that because of the extent of some of the issues discovered it would be best to tear the bike down to the frame and split the cases.

Keep in mind that we are NOT going to change or modify any part of this bike that will affect performance. We want to keep the bike in the same state that the previous builder intended. The reason behind this is that we plan to compare this bike in its original form to the other project bike that we are building for the magazine test. Once the magazine has written their article on the two different KX500's this one will go back under the knife to be built the KX Guru Racing way.

We will only alter things that affect engine longevity and rider comfort like oil passages, shift quality, cable routing, etc. and nothing that will alter the current performance characteristics.

I can also guarantee that in the hands of KX Guru Racing and under the supervised eye of my 11 month old daughter this EXTREME budget build will still be a better build than what was originally given to Sean 18 months ago.

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