Maintenance & Technical > KX500 Original
Tight countershaft
yeomans:
Okay, so I just got around to fitting up another left case off of my other 86.
Same issue countershaft is tight.
Now I am really scratching my head.
motopunk:
i read all the posts in this thread again. and now my question what year is the engine and what year the trans-shafts??
... 83-87 have a nut on the countershaft to fix the countersprocket ... 88-2004 a snapring and the 88 and newer transshafts wont never fit correctly to the older cases without machining and make the clamp-effect ... dont know why,because it looks so similar, like it would fit, but i tried it and does not work ... 88 have exactly same transmission like the 89 -2004, except the shorter second gear that was changed in 89..( i have the longer second gear installed in my 86 , because worn out and also discontinued and it works way better.. :-). )
maybe here sits the cat before the mouse-hole, that you have not the right countershaft to this engine..
1986kx500 transmission
http://www.cmsnl.com/kawasaki-1986-b2-kx500_model11966/partslist/B9.html#results
1988 the washer 92022, that you spoke off, is on the inputshaft not on the outputshaft, where´s your problem
http://www.cmsnl.com/kawasaki-1988-d1-kx500-north-america_model11968/partslist/E1361.html#results
1989-2004...
http://www.cmsnl.com/kawasaki-1989-e1-kx500-north-america_model11970/partslist/E1361.html#results
...as long you dont find the problem with wrong shafts you have to re-machine the welded areas to the oem-cases-measurements... thats now the 2 points, you have to watch out... :wink:
yeomans:
Thanks MP,
The cases and trans are both from and 86. The countershaft has the nut for the sprocket.
I have 2 1986 motors, so I have been playing around with fit of different countershafts and different case halves. Which frustrates me when a completely different case half locks the shaft as well.
Still haven't tried using my other right case yet because I hadn't had any welding done there, but that might be a place to check as well.
I just replaced all the bearings with new oem parts except the crank bearings which were from Wiseco, but they still say Koyo with the same numbers printed on the bearing as what came stock, and new seals. Yesterday I rechecked all the bearings as well.
Rick james:
Just to throw my .02 in here, mine was running before I tried this and I've got the same issue. The guy I talked to about rebuilding my bottom end thinks it's a bad bearing that's causing it to lock up.
motopunk:
--- Quote from: yeomans on March 23, 2014, 12:44:03 AM ---Thanks MP,
The cases and trans are both from and 86. The countershaft has the nut for the sprocket.
I have 2 1986 motors, so I have been playing around with fit of different countershafts and different case halves. Which frustrates me when a completely different case half locks the shaft as well.
Still haven't tried using my other right case yet because I hadn't had any welding done there, but that might be a place to check as well.
I just replaced all the bearings with new oem parts except the crank bearings which were from Wiseco, but they still say Koyo with the same numbers printed on the bearing as what came stock, and new seals. Yesterday I rechecked all the bearings as well.
--- End quote ---
thats just for headscratching... measurements of the bearings are worldwide the same norm, so it normally must fit together like before the disassembeling...it is possible, that the big bearing on the left side is a little bit wider and takes the space that the output shaft needs between the cases.. (just a thought) so it must be the shaft the problem, if the bearings and seals are installed correctly ..
do you tried to install the transmission only, without the crank? so you can check also with only input-shaft or only outputshaft between the cases, where the problem is sitting directly... little ko-system... :wink:
you´re to far away for practical help, if i could see it directly before my eyes , i could help better.
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