Maintenance & Technical > KX500 Original

Crank instalation

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Pmcg:
Im getting ready to rebuild my kx500 and have read a few different techniques for installing the crank.  Are there any advantages to pressing the crank into the case using the Kawasaki crankshaft jig over pulling the crank into the case with the tusk crank installer? The crank is being rebuilt and balanced at Pinsonnault and I really don't want to do it twice!  I am always looking for a reason to buy a few new tools but am quickly running out of kx money.  Any advice/techniques are appreciated.   

Motorrad:

--- Quote from: Pmcg on July 07, 2013, 03:53:17 PM ---Im getting ready to rebuild my kx500 and have read a few different techniques for installing the crank.  Are there any advantages to pressing the crank into the case using the Kawasaki crankshaft jig over pulling the crank into the case with the tusk crank installer? The crank is being rebuilt and balanced at Pinsonnault and I really don't want to do it twice!  I am always looking for a reason to buy a few new tools but am quickly running out of kx money.  Any advice/techniques are appreciated.   

--- End quote ---

I don't use either tequnique

Pmcg:
haha in reading through archived posts I know I'm not the first person to type this.  Hey Motorrad care to elaborate? 

Motorrad:
From several places on the site.

if you look at my or USMC'500's motor build thread... you will notice there are pictures where the crank is frozen ....



Here is my order.... Not for the faint of heart, or the SLOW worker.. as it all happens VERY VERY fast..

Get a Beer...

I install crank seals, then mains in the cases Using Heat/freeze method (drink a beer)....   install tranny...  (dont forget to GREASE ALL SEALS and yamabond the seals in)  

Oil crank.... put in freezer overnight... Have another beer or 4

Next day... turn oven on to 500F..   put in 4 impact sockets, that are same size as "inner race" on mains.. Have a beer.


let sockets heat for about an hour... or so.. have 2 beers

take 2 sockets out... Place on the inner race of each case.. for about 4min... This method keeps all heat away from crank seals (your next to the freezer, get another beer)

While those are on there... Put Case sealer on Primary side case..

Get other 2 sockets... Place on mains (take other 2 off).. (need another beer?)

let sit for 2 min... then go get the crank (my freezer is a 1min round trip from bench).. (no time for beer need to work fast at this point.)


Drop crank in Clutch side case (the one the tranny is in)... it will fall all the way through and go "CLUNK" against the main...  (have to have case proped up so crank end wont hit bench).. I have a universal motor stand built out of 2x4's for this...

Imediatly get ignition side case.. and Drop on...

Make quick sure it spins free and is centered..   now is the quick time for a light tap with a rubber hammer to undo any bind your in...

Install Case bolts you ALREADY HAVE LAYED OUT.. In order... along with proper tools.....

Torque to half spec...
...........Have a sip of beer................  
Torque to full spec...

Have a beer.. you did good..

Motorrad:
PS    all my bearings and cranks go in with retaining compound.      K5 is famous for slippen em.

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