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

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Sandblaster
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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 4:48 am

Sweet!
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Wed Oct 05, 2016 3:39 am

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.
KX GURU RACING SEAN COLLIER KX500 177.JPG
KX GURU RACING SEAN COLLIER KX500 177.JPG (124.62 KiB) Viewed 2701 times
KX GURU RACING SEAN COLLIER KX500 178.JPG
KX GURU RACING SEAN COLLIER KX500 178.JPG (91.68 KiB) Viewed 2701 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.............. :D
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Wed Oct 05, 2016 3:45 am

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.
KX GURU RACING SEAN COLLIER KX500 187.JPG
KX GURU RACING SEAN COLLIER KX500 187.JPG (234.04 KiB) Viewed 2698 times
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..
KX GURU RACING SEAN COLLIER KX500 180.JPG
KX GURU RACING SEAN COLLIER KX500 180.JPG (256.41 KiB) Viewed 2698 times
KX GURU RACING SEAN COLLIER KX500 181.JPG
KX GURU RACING SEAN COLLIER KX500 181.JPG (241.1 KiB) Viewed 2698 times
The fact is I was going to save this case for something special so it's going to a good cause ;)
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Sandblaster
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Wed Oct 05, 2016 3:50 am

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 :o :shock: :o
KX GURU RACING SEAN COLLIER KX500 179.JPG
KX GURU RACING SEAN COLLIER KX500 179.JPG (349 KiB) Viewed 2697 times
The Fork on the right has the tips polished. The fork on the left is not polished.
KX GURU RACING SEAN COLLIER KX500 186.JPG
KX GURU RACING SEAN COLLIER KX500 186.JPG (177.7 KiB) Viewed 2697 times
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.... :geek:

The left shift fork pin is polished, the right is not.
KX GURU RACING SEAN COLLIER KX500 184.JPG
KX GURU RACING SEAN COLLIER KX500 184.JPG (131.8 KiB) Viewed 2697 times
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by USMC 500 » Wed Oct 05, 2016 6:56 am

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

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

Post by Sandblaster » Wed Oct 05, 2016 1:06 pm

Don't spare the thread locker :lol:
If bikes are for kids I'll never grow up.

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

Post by Sandblaster » Wed Oct 05, 2016 8:16 pm

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

Before..
KX GURU RACING SEAN COLLIER KX500 178.JPG
KX GURU RACING SEAN COLLIER KX500 178.JPG (184.9 KiB) Viewed 2688 times
After..
KX GURU RACING SEAN COLLIER KX500 179.JPG
KX GURU RACING SEAN COLLIER KX500 179.JPG (176.6 KiB) Viewed 2688 times
If bikes are for kids I'll never grow up.

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

Post by Sandblaster » Wed Oct 05, 2016 8:17 pm

Other side... Before..
KX GURU RACING SEAN COLLIER KX500 180.JPG
KX GURU RACING SEAN COLLIER KX500 180.JPG (209.91 KiB) Viewed 2687 times
After...
KX GURU RACING SEAN COLLIER KX500 181.JPG
KX GURU RACING SEAN COLLIER KX500 181.JPG (211.61 KiB) Viewed 2687 times
If bikes are for kids I'll never grow up.

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

Post by Sandblaster » Wed Oct 05, 2016 8:18 pm

It would be a lot easier if someone would spring for a new set of factory cases..
KX GURU RACING SEAN COLLIER KX500 182.JPG
KX GURU RACING SEAN COLLIER KX500 182.JPG (131.73 KiB) Viewed 2686 times
Too bad you can't get them any more.... :o :( :cry:
If bikes are for kids I'll never grow up.

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

Post by Sandblaster » Thu Oct 06, 2016 12:02 am

A little time with a buffing wheel and some polishing compound goes a long way..
KX GURU RACING SEAN COLLIER KX500 183.JPG
KX GURU RACING SEAN COLLIER KX500 183.JPG (108.61 KiB) Viewed 2684 times
Shift fork shaft... One of many parts being polished to improve shifting..
KX GURU RACING SEAN COLLIER KX500 184.JPG
KX GURU RACING SEAN COLLIER KX500 184.JPG (259.49 KiB) Viewed 2684 times
If bikes are for kids I'll never grow up.

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