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1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Fri Dec 11, 2015 12:50 am
by Sandblaster
This was a interesting engine that came to us.
The base of the cylinder was machined .040", the squish on the head was .045", the timing was retarded, and the boost ports were hogged out.
Someone was looking for some more torque
But this customer want's HP and some more top end so we aim to please...
- OEM-CYCLE.COM 1999 KX500 KAWASAKI BUILD FOR KEVIN 101.JPG (149.95 KiB) Viewed 9112 times
- OEM-CYCLE.COM 1999 KX500 KAWASAKI BUILD FOR KEVIN 102.JPG (125.63 KiB) Viewed 9112 times
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Fri Dec 11, 2015 12:52 am
by Sandblaster
Parts come to us like this..
- OEM-CYCLE.COM 1999 KX500 KAWASAKI BUILD FOR KEVIN 103.JPG (55.38 KiB) Viewed 9111 times
But they go back out more like this...
- OEM-CYCLE.COM 1999 KX500 KAWASAKI BUILD FOR KEVIN 105.JPG (52.3 KiB) Viewed 9111 times
- OEM-CYCLE.COM 1999 KX500 KAWASAKI BUILD FOR KEVIN 104.JPG (49.37 KiB) Viewed 9111 times
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Fri Dec 11, 2015 9:04 pm
by Sandblaster
Ordered the rod today.
We will wait for it to get here then polish it.
Then we will send it out for balancing, and rebuilding.
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Sun Dec 13, 2015 3:33 pm
by Sandblaster
The trans needed 3rd and 4th both input and output
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Fri Jan 15, 2016 3:54 am
by Sandblaster
Balanced and ready for assembly.
- !cid_20160114_161126.jpg (141.42 KiB) Viewed 9064 times
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Tue Feb 16, 2016 2:29 am
by Sandblaster
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Tue Feb 16, 2016 2:38 am
by Sandblaster
Dirt things first, gotta remove all the bearings, seals, and bearing retainers..
- 20160215_162912.jpg (359.44 KiB) Viewed 9026 times
Shish Kebab!!!
- 20160215_162941.jpg (413.24 KiB) Viewed 9026 times
When lapping you can have your buddy hold the cases for you or.....
- 20160215_165344.jpg (417.6 KiB) Viewed 9026 times
Timesaver is the best stuff out there for lapping aluminum..
- 20160215_170330.jpg (355.39 KiB) Viewed 9026 times
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Tue Feb 16, 2016 2:42 am
by Sandblaster
Gotta get the Timesaver on the entire surface
- 20160215_170332.jpg (363.75 KiB) Viewed 9026 times
This is the typical trouble area for KX500's... Note where the dark grey is around the edges of the cases.
Then look at the yellow area.
The yellow area means that the cases have a gap there.
- 20160215_170500.jpg (379.77 KiB) Viewed 9026 times
So rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl...
- 20160215_171724.jpg (332.98 KiB) Viewed 9026 times
Now they are dark grey all around which means they are ready for clean up, porting, and repair,,
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Wed Feb 17, 2016 5:30 am
by Sandblaster
Look at that cute little hole that feeds the main bearings...
- 20160216_123618.jpg (159.26 KiB) Viewed 9018 times
That's better, enlarged and countersunk
- 20160216_124136.jpg (147.36 KiB) Viewed 9018 times
Now look at this oil transfer hole.... See how high it is from the floor of the case?
When you drain the oil, this will leave some behind...
- 20160216_125414.jpg (298.18 KiB) Viewed 9018 times
Problem solved
- 20160216_171354.jpg (104.03 KiB) Viewed 9018 times
Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Posted: Wed Feb 17, 2016 5:34 am
by Sandblaster
There are other improvements made but I can't show you them all
