1993 KX500 Engine build for Jeff Y

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Jeff brought his entire bike down to the shop.
Jason made short work of the disassembly..

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Jeff is making sure Jason does it right

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This crank is done but Jason will have it pristine before long..

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I hate case damage but Jason can get it in great working condition..

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Like most builds this engine needs a good cleaning..

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Here is the case and the clutch cover baking after vapor blasting.
Our welder loves how clean we get the parts

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It was hard to see but the other case was cracked as well... No biggie... Jason will get it fixed up good as new..

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I know it's a minor part but the shift lever came in today... 20mm longer then stock...
Of course we had to change out the shift shaft to the 94-04 so that the splines would fit but I think it is well worth the upgrade.
I like mine..

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Jason is hard at it...
It's amazing how many hours it takes to do a nice porting job...

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Still hard at it... Same cylinder, different day...

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After doing the base porting, Jason is Vapor Blasting the cylinder to clean it up.
Once it is done it will get all final port work then it will go off to plating.
Once it comes back, it will get the final Vapor Blasting and then polishing, clean up, then assembly..
Still a lot of work to do..

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I don't think most people fully grasp how much work Jason's level of porting takes.
Here is a bit of a secret.
In the first hour to hour and a half you can get 80-85% of the basic port work done, or something comparable to E. Gore, or some of the other big name shops. To get that last 15-20% takes more and more time.... But if your looking for a quality port job you won't see much if any better then Jason's work any where...

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It's like pulling teeth to get the Wossner Pistons and Rod kits....
I guess I should not have told so many people how good they are

I finally tapped all the holes for the 2 piece clutch cover..

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It's gonna look great.

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