Before
- 91 KX500 CLUTCH BASKET REPAIR OEM-CYCLE.COM 120.JPG (72.41 KiB) Viewed 10766 times
- 91 KX500 CLUTCH BASKET REPAIR OEM-CYCLE.COM 121.JPG (51.36 KiB) Viewed 10766 times
Building a 91 KX500 engine
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Sandblaster
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- Location: Eugene, OR
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Re: Building a 91 KX500 engine
Clutch basket repair...
Before
After
Jason is a master with a hand file and Scotch Brite
Before
After
Jason is a master with a hand file and Scotch Brite
If bikes are for kids I'll never grow up.
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Sandblaster
- Posts: 6320
- Joined: Thu Jun 07, 2012 3:50 pm
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Re: Building a 91 KX500 engine
Drain plug repair is complete.
I like to make them a little deeper then stock so that you have more thread engagement and less chance of stripping in the future.
I also put WD40 in the case and let it sit over night to make sure it is not leaking before assembly.
I like to make them a little deeper then stock so that you have more thread engagement and less chance of stripping in the future.
I also put WD40 in the case and let it sit over night to make sure it is not leaking before assembly.
- 91 KX500 DRAIN PLUG REPAIR OEM-CYCLE.COM 123.JPG (28.19 KiB) Viewed 10766 times
- 91 KX500 DRAIN PLUG REPAIR OEM-CYCLE.COM 124.JPG (10.38 KiB) Viewed 10766 times
If bikes are for kids I'll never grow up.
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Sandblaster
- Posts: 6320
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Re: Building a 91 KX500 engine
Not quite factory but still functional.. 
If bikes are for kids I'll never grow up.
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Sandblaster
- Posts: 6320
- Joined: Thu Jun 07, 2012 3:50 pm
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Re: Building a 91 KX500 engine
Clutch hub before
After
Not perfect but a whole lot better then before.
This should provide a little easier clutch pull.
- 91 KX500 CLUTCH HUB REPAIR OEM-CYCLE.COM 125.JPG (40.56 KiB) Viewed 10764 times
- 91 KX500 CLUTCH HUB REPAIR OEM-CYCLE.COM 126.JPG (23.34 KiB) Viewed 10764 times
This should provide a little easier clutch pull.
If bikes are for kids I'll never grow up.
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Sandblaster
- Posts: 6320
- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
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Re: Building a 91 KX500 engine
Getting the clutch plates pre oiled..
- 91 KX500 CLUTCH PRE OILING OEM-CYCLE.COM 127.JPG (66.51 KiB) Viewed 10763 times
If bikes are for kids I'll never grow up.
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Crofter985
- Posts: 240
- Joined: Mon Nov 10, 2014 6:47 pm
- Location: Shetland Islands, UK
Re: Building a 91 KX500 engine
Nice work mike. Good to see that timesaver stuff in action, I did not lap my cases, perhaps I should have. I guess if they don't leak oil they are ok?
Anyway it's going to be one clean and pretty engine when it's done.
Anyway it's going to be one clean and pretty engine when it's done.
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Sandblaster
- Posts: 6320
- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
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Re: Building a 91 KX500 engine
If you have no leaks most likely you are ok.
Four strokes don't have as many issues with air leaks that the two strokes do.
If you have a hard time getting the timesaver let me know and I will pick you up a can.
Four strokes don't have as many issues with air leaks that the two strokes do.
If you have a hard time getting the timesaver let me know and I will pick you up a can.
If bikes are for kids I'll never grow up.
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Crofter985
- Posts: 240
- Joined: Mon Nov 10, 2014 6:47 pm
- Location: Shetland Islands, UK
Re: Building a 91 KX500 engine
Do you know how much it would be to ship a couple of cranks, a set of cases and a head of you have one? Like if they were all in a box. FedEx or a company like that would probably be best, Eh? And how much for the parts?
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Sandblaster
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- Joined: Thu Jun 07, 2012 3:50 pm
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Re: Building a 91 KX500 engine
I'll see what I can do for you...
If bikes are for kids I'll never grow up.
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Sandblaster
- Posts: 6320
- Joined: Thu Jun 07, 2012 3:50 pm
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Re: Building a 91 KX500 engine
As if it weren't clean enough already...
- 91 KX500 OEM-CYCLE.COM MORE CASE CLEANING 106.JPG (94.98 KiB) Viewed 10749 times
If bikes are for kids I'll never grow up.