Cleaning up my KX500 cylinder before plating

[Sandblaster]

I was asked by a guy how could I tell if something was a casting flaw or if it was intentional.
That's a good question....
Motorrad has helped me tremendously on this.
It also helps if you have another cylinder or two to compare with...



If there is a big wad of rough jibbly gunk on one cylinder but the other 3 stock cylinders don't have it, I think it's a safe bet that it can be removed.
Then again there is always the exception to the rule....
If your not sure, better leave it.

[Sandblaster]

Thanks to Motorrad I was further examining the fitment between the cylinder and the engine cases.



Looks like some improvement is required...
Then I checked out this cylinder that was removed from a bottom end on Friday.
Notice the gasket material hanging into the ports?
BAD!
Before my gasket goes on it will be matched.

[Sandblaster]

I really like this article:

http://www.hallbergs.net/kx500/

[Sandblaster]

The following questions are for Motorrad but others feel free to join in

more clean up 4.JPG (87.26 KiB) Viewed 13032 times

more clean up 5.JPG (39.79 KiB) Viewed 13032 times

[Sandblaster]

I've been working on the exhaust port polishing..
What a job.
Check out this casting flaw...

EXHAUST PORT CLEAN UP 2.PNG (333.33 KiB) Viewed 13003 times

It's the same on both sides...

[Motorrad]

you wouldnt happen to have a jug you want to part with do ya? (sell)....

or a GOOD crank?

[Sandblaster]

Cylinder.... Maybe....
Crank.... I'll check tomorrow and let you know...

[Motorrad]

those nasty cracks you want to watch for.

[Motorrad]

Food coloring is a good way to test for cracks. its alc based... so it CREAPES everywhere.. put a little dab in the middle of the crack.. and see where it ends up..

look close at the far port. you can see the crack goes LONG WAY down. right along the casting seam... *(where all the cracks show up)

[Sandblaster]

That's a good trick using food coloring....
I'm assuming that's USMC 500's cylinder?
I'll see what I can find tomorrow.