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

Bike Builds and rebuilds. Post pics and discuss your projects.
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Sat Oct 22, 2016 1:22 am

KX GURU RACING SEAN COLLIER KX500 284.JPG
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KX GURU RACING SEAN COLLIER KX500 285.JPG
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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 » Sat Oct 22, 2016 1:24 am

Ready for final packaging..
No, I don't ship them in a cardbaord box unless it was a very special box and this one isn't :)
KX GURU RACING SEAN COLLIER KX500 286.JPG
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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 » Sun Oct 30, 2016 4:37 pm

Making progress but this has to be done in 4 more days... :shock:
KX GURU RACING SEAN COLLIER KX500 301.JPG
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by Sandblaster » Wed Nov 02, 2016 4:03 am

Wrapping up this build is a bit scary.
Oscar is assembling the bike down in S. Cal.
He should be able to put some heat cycles on it and ride it on Friday to break it in.
Sean races on Saturday :shock:

What we did to this engine to freshen it up was not what we wanted to do.
It was all we were allowed to do.
I saw a lot of room for improvement but that was just the point.
They didn't want any improvements other then longevity and better shifting.
I will get more into that later.. Cool things are coming 8-)
But here is the basic list:
Disassemble, clean, and carefully inspect EVERYTHING.
Vapor blast all the aluminum, and polish everything that could be polished, head, trans gears, trans shafts, ect.
Replaced all the shift components with used but in spec parts.
All were hand polished.
Replaced the clutch plates.
Hand ground the dogs on the trans gears.
Replaced the piston and Ring set with a very low hour set from my own bike.
Every bearing, seal, and gasket, was replaced.
Hand filed the clutch basket ears and the clutch hub, then polished them.
The left engine case was replaced as the existing one was junk.
Hand lapped the cases, cylinder, and head.
Disassembled the carb, cleaned it thoroughly, reset the floats, and set the screws to how they were when we received it.
It really could have used a plate job but we just didn't have the time or the money to do it.
Also, some of the gears were pretty poor but I think after Jason tuned them up they should be ok for a while.
So, it wasn't what we would have liked to do but it should survive until we get Sean's new bike built.
If bikes are for kids I'll never grow up.

USMC 500
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by USMC 500 » Thu Nov 03, 2016 4:13 am

ITS ALIVE!! The Beast fired up in 4 kicks and got 2 heat cycles so far. One more heat cycle to go then a torque check on the head and jug. Friday I will be taking the Beast out for the break in ride and then to the Dubya Vet Nationals at Glen Helen on Sunday where Sean will let her rip!! Big Thanks to the boys of KX Guru Racing for giving the Beast a second chance.

https://youtu.be/40A2t0HTEBA

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

Post by Sandblaster » Sat Nov 05, 2016 8:14 am

Today Oscar broke in the new engine.
Tomorrow he will put on all the new parts so take one last look at this bike,
This is the last time you will see it in this trim.
Seans bike is ready for Glen Helen.jpg
Seans bike is ready for Glen Helen.jpg (38.62 KiB) Viewed 1736 times
When you see it on Sunday it will have taken it's first steps to becoming KX Guru'd :lol:
world vet.png
world vet.png (373.62 KiB) Viewed 1736 times
I sure wish I was going... :cry:
If bikes are for kids I'll never grow up.

USMC 500
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Re: Sean Colliers KX500 Project "I was only going to inspect the top end"

Post by USMC 500 » Sat Nov 05, 2016 9:12 am

The Beast now has a total of 1.2 hours on the hour meter. The 2 most noticeable improvements on the Beast are the Chassis and the Tranny.

The Beast was treated to Pivot Works bearings all the way around.....wheels, steering, shock linkage, shock and swingarm. This bike feels very tight and has the feeling of a brand new motorcycle.

The Transmission......Mike and Jason did a phenomenal job getting the transmission to function properly. Previously the transmission would jump out of gear and you would have to really slam the shifter to make gear changes under load. The transmission now shifts like butter. The shift lever gives zero resistance when making gear changes and inspires confidence.

The motor is no slouch either. I spent the first hour just cruising around to get all the new engine parts to mingle and meet. Just before loading the Beast I made about 5 good 5th gear WOT passes and the Beast passed with flying colors. There is a little work that still needs to be done as far as jetting goes but that will get done at the race on Sunday.

Tomorrow will be another busy day.......there is still much to be done before Sunday's race:

Wash the bike
Torque check the head and cylinder again
change the gearbox oil
Modify and install new Torc 1 rear brake lever
Install new Torc 1 handlebar and grips
Install and test fit new Torc 1 foot pegs
clean the air filter :shock: ........those who know the history of MY bike will understand. lol
Install new factory FMF pipe and silencer
Mount all new bodywork

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

Post by Sandblaster » Sat Nov 05, 2016 3:02 pm

We are coming down to round one with the beast....
We shall see what happens.
Nice job on the chassis prep and assembly Oscar.
Few people will ever understand what you went through on this rebuild...
I'm really looking forward to seeing how Sean likes the suspension...
I'm certain that Alex is wondering as well :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 » Sat Nov 05, 2016 3:15 pm

Break in ride pic... Much more is coming on that..
Seans bike is ready for Glen Helen 2.jpg
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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 » Sun Nov 06, 2016 5:14 pm

Oscar finished assembling the bike late last night...
KX GURU RACING SEAN COLLIER KX500 307.JPG
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If bikes are for kids I'll never grow up.

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