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

[Sandblaster]

Sweet!

[Sandblaster]

I was doing some more clean up at the bottom of the cylinder and discovered that the plating is wearing through at the bottom of the exhaust port.

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KX GURU RACING SEAN COLLIER KX500 178.JPG (91.68 KiB) Viewed 6941 times

But, we are not rebuilding anything on this except for addressing the shifting issues.
And to do that we had to split the cases... so..............

[Sandblaster]

The left main seal was leaking.
I was told that there was some sort of repair done there.
Sure enough, the main bearing journal was bored out then sleeved.
In practice, this would be an excellent repair.
Unfortunately this one was not carried out correctly.
I believe that it is out of round which may be helping contribute to the intense vibration this motor puts out.

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Going back to our original mandate which was to fix the shifting issue I really should just put it back together as is..
However, I can't justify it so I rounded up this replacement case..
She is a beauty..

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KX GURU RACING SEAN COLLIER KX500 181.JPG (241.1 KiB) Viewed 6938 times

The fact is I was going to save this case for something special so it's going to a good cause

[Sandblaster]

I compared 3 sets of shift forks to find the set with the least amount of wear.
I actually compared these two used sets to a brand new factory set still in the package.
Believe it or not, some of the used parts were closer to new spec then the new forks

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The Fork on the right has the tips polished. The fork on the left is not polished.

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Even though this is a major budget build and we are only suppose to fix the shifting issue, the goal is to make it shift better then any other KX500 Sean has rode to date.
On Sean's all new bike we will surpass this bike....

The left shift fork pin is polished, the right is not.

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[USMC 500]

Sorry I don't have any cool pictures to post right now as I have been running around trying to balance a primary job, a life and both of these project bikes. My extreme gratitude and appreciation to Sandblaster for helping me carry a good portion of the load. I will have photos to post later but below are some of the details that I am currently working on my end.......

1. Replacement frame (original frame has cracked linkage tabs) is currently in paint to get a fresh coat and then brand new steering stem bearings and races will be installed and all engine and electrical mounting points will be ground to bare metal and all threads will be chased and cleaned - to be picked up Thursday

2. Sub frame is currently at AC racing getting some of the threaded inserts fixed and/or replaced - to be picked up Thursday

3. Sean's original shock with Enzo internals should be arriving at Alwards door tomorrow and he will be inspecting and sending me the shock either rebuilt with Race Tech Valves or a replacement shock of his own with Race Tech Valves

4. Steering stem bearings, shock bearings, linkage bearings, swing arm bearings and both wheel bearings are going to be replaced by me tomorrow

5. IMS foot pegs have been re-sharpened with a grinder

6. New tires being mounted front and rear

7. Front and rear brakes are getting new pads and fresh fluid

8. Air box is being disassembled, thoroughly cleaned and re-assembled and sealed

9. New chain guide blocks, chain and sprockets are being mounted along with a gearing change from 14/51 to 13/45 that Sean requested after he rode my bike with 13/45 and to save the new chain guide block by making the rear sprocket smaller and reducing the drag across the chain guide

10. New 2004 KX500 kick start lever will be mounted once the engine is in place to replace the one that snapped off

11. Good quality replacement clutch cable will be lubed and installed using Team Green routing to replaced the damaged cable that came off

12. New Hammerhead rear brake lever and clevis will be installed in place of the stocker

13. New front motor mount will be used to replace the broken mount that came off the bike

14. A Works Connection combination Hour Meter/Tachometer will be installed to keep track of hours and RPM data after the rebuild

15. New UFO rear fender and fresh graphics will be installed

[Sandblaster]

Don't spare the thread locker

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Ok, took the cases down to a local machine shop and ran the cases on a surface machine..

Before..

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After..

KX GURU RACING SEAN COLLIER KX500 179.JPG (176.6 KiB) Viewed 6928 times

[Sandblaster]

Other side... Before..

KX GURU RACING SEAN COLLIER KX500 180.JPG (209.91 KiB) Viewed 6927 times

After...

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[Sandblaster]

It would be a lot easier if someone would spring for a new set of factory cases..

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Too bad you can't get them any more....

[Sandblaster]

A little time with a buffing wheel and some polishing compound goes a long way..

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Shift fork shaft... One of many parts being polished to improve shifting..

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