1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN

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Getting ready to repair the counter sprocket guard post or tower..

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So here I have a beautifully ported and plated cylinder that has zero hours on it...

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And what am I gonna do?

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I almost cried

This is gonna be a rocket...

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Tearin it up

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The head was fairly rough so this is about the best we could do without re-cutting the head.

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It's all roughed out and waiting for the bottom end to get assembled.
As soon as that is done we will assemble the top end, get the finish dimensions, and send it off for machine, weld, and final plating

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Counter sprocket bolt tower is done.
I didn't like how the 6mm tap job came out so I used two helicoil's to get the thread engagement all the way to the bottom.
It wasn't really necessary but why not?

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So, you think those cases are clean?
Not so fast buddy....
There is many little places for the old seal;ant to hide.

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This is from one case

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So, the cases are well prepped.
Jason is washing them with soap and water right now as well as chasing all the bolt holes.
The idea is to have not one spec of debris left in the engine...

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All the transmission parts have been cleaned including the clips and all the new gears.
This one has many new gears including both 3rds and 4ths.

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