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2002 KX500 Kawasaki engine rebuild for Greg
Posted: Sat Mar 12, 2016 8:13 pm
by Sandblaster
When you are rebuilding your KX500 engine this is not a good sign..
https://youtu.be/mzAoHiYxiqs
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Mon Mar 14, 2016 7:38 pm
by Sandblaster
On this build we were hoping to save the crank and the top end and simply replace all the bearings, seals, washers, snap rings, bushings, ect.
This is what we received..
- JT Engine works kx500 rebuild 101.JPG (146.75 KiB) Viewed 12769 times
Looks good...
The head came off and.... Looks good as well...
- JT Engine works kx500 rebuild 102.JPG (101.4 KiB) Viewed 12769 times
Recorded the head squish
Piston and cylinder bore look decent..
- JT Engine works kx500 rebuild 103.JPG (80.03 KiB) Viewed 12769 times
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Mon Mar 14, 2016 7:40 pm
by Sandblaster
With a weight like that, this is definitely a trail rider
- JT Engine works kx500 rebuild 104.JPG (210.57 KiB) Viewed 12769 times
Gonna need some new reed pedals..
- JT Engine works kx500 rebuild 105.JPG (87.9 KiB) Viewed 12769 times
Measure and record the piston at TDC to the cylinder deck..
- JT Engine works kx500 rebuild 106.JPG (94.79 KiB) Viewed 12769 times
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Mon Mar 14, 2016 7:47 pm
by Sandblaster
Gonna need some welding and fab work
- JT Engine works kx500 rebuild 107.JPG (113.66 KiB) Viewed 12769 times
Measure and record the ports.... All stock.... Ignore the reading on the wheel
- JT Engine works kx500 rebuild 108.JPG (96.08 KiB) Viewed 12769 times
Here is where we found some issues..
- JT Engine works kx500 rebuild 109.JPG (84.41 KiB) Viewed 12769 times
The piston is a bit buggered up...
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Mon Mar 14, 2016 7:50 pm
by Sandblaster
Unfortunately the piston wall is getting thin and it's got a dink in it.....
- JT Engine works kx500 rebuild 110.JPG (49.96 KiB) Viewed 12769 times
Also the crank has some strange grinding marks on the side of it..
- JT Engine works kx500 rebuild 111.JPG (131.02 KiB) Viewed 12769 times
It also has a lot of galling around the flywheel.... hmmmmm
- JT Engine works kx500 rebuild 112.JPG (82.49 KiB) Viewed 12769 times
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Mon Mar 14, 2016 7:56 pm
by Sandblaster
Then a closer inspection of the plating reveals some thin plating and some issues around the ports..
- JT Engine works kx500 rebuild 113.JPG (60.21 KiB) Viewed 12769 times
Maintenance was not a issue on this bike.
Look how clean it is on the inside..
- JT Engine works kx500 rebuild 114.JPG (264.01 KiB) Viewed 12769 times
The customer uses Royal Purple Synthetic 10/30
- lrg_1457918265495_0071591589_d86e4ee0_v1.jpg (80.63 KiB) Viewed 12769 times
I've been thinking about trying it for some time..
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Mon Mar 14, 2016 7:58 pm
by Sandblaster
Helicoil drain plug... We may have to fix this..
- JT Engine works kx500 rebuild 115.JPG (61.95 KiB) Viewed 12769 times
Hmmm, I'm not certain what balance factor they were shooting for but these holes are a no go..
- JT Engine works kx500 rebuild 116.JPG (117.32 KiB) Viewed 12769 times
It's a shame that this top end has very little time on it and for some reason it has some issues..
- JT Engine works kx500 rebuild 117.JPG (235.44 KiB) Viewed 12769 times
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Mon Mar 14, 2016 8:00 pm
by Sandblaster
Nice, clean, stock cylinder
- JT Engine works kx500 rebuild 118.JPG (151.25 KiB) Viewed 12769 times
I'll fix that
Got some roughing work to do..
- JT Engine works kx500 rebuild 119.JPG (204.8 KiB) Viewed 12769 times
- JT Engine works kx500 rebuild 120.JPG (217.56 KiB) Viewed 12769 times
- JT Engine works kx500 rebuild 121.JPG (289.74 KiB) Viewed 12769 times
I finished the porting at about 12:30 this afternoon and got it shipped to Millennium Tech for plating... Oh yeah!
No, these pics are of the roughing work, not the finished cylinder
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Wed Apr 13, 2016 12:41 am
by Sandblaster
Re: 2002 KX500 Kawasaki engine rebuild for Greg
Posted: Wed Apr 13, 2016 12:43 am
by Sandblaster