Maintenance & Technical > KX500 Original
...on my big green tractor (91 KX500 Build)
jgturbo:
Flywheel puller finally came in. Here's the breakdown:
Ready to come apart:
There's third gear! Popped the clip out of the groove:
Here's why the clip popped out (probably combined with a slightly bent shift fork):
Found the main bearing play. The cases are ok!
Explosion on the workbench:
Notice the DeWalt impact driver. I highly recommend it for working on bikes. Plenty of energy to knock fasteners loose in a really small package. MUCH better than spinning wrenches in my book. Ziiip ziiip ziiiip done!
jgturbo:
I'm in the market for a service manual (pdf would be cool)... PMs welcome.
Brute:
Just was reading this again and noticed you are in Washington! Have decided to SM and plate mine, but will probably Rim-n-spoke an extra set of wheels so I can throw the stock ones back on if I want to dirt the bike again quicky. Told a guy at work about the 'plan' and he went ape about it. He is a road racer that rode for Cagiva over seas. He would be a good choice to have wring it out at a track me thinks! Got to get it built first. Good to see you found the slop problem in the crank. Are you going to get it metal sprayed, welded, or just replace it?
jgturbo:
I'm actually in Portland, so it's registered in Oregon. I don't know yet what I'll do with the crank. Can someone recommend a crank repair shop that could fix this? Otherwise I might try to grab one off eBay and have it rebuilt.
jgturbo:
Picked up a crank assembly from an '04 on ebay. It's got to be in better shape than mine.
Also made a bit of progress on the cylinder:
Cutting .050 off the top (super low quality video):
A couple minutes with a stone yielded this:
I should now have close to zero deck clearance. I'll be fine tuning the squish with base gaskets.
Now I need to research head designs so I can 3D mill my squish band and combustion chamber 8-)
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