Maintenance & Technical > KX500 Original
1993 Rebuild....and Intro
brucifer:
Hey guys, new KX500 owner here. I've been riding since I was 4 years old--mainly four-strokes with the occasional two-stroke thrown in. I'm now 48.
I just sold an '84 CR500 so I'm not a noob to 500cc two-strokes but I am to the mighty KX500.
I had posted a wanted ad on CL for a dirt bike project and was offered this bike. The PO had purchased it from a neighbor who pretty much didn't know the meaning of the word maintenance. The gentleman I purchased it from gave me a list of everything he did to it and what he thought needed attention. The bike had not run since the PO bought it from his neighbor but I was assured it did run.
When it was delivered to me, I checked it over and discovered it had decent compression but something felt "loose" when I kicked it over. I got it on compression and grabbed the kickstarter with my hand and kinda moved it against compression and relaxed, against compression, relaxed a few times and could feel play and could hear a muted kind of a "clank" in the top end. The first thing I thought of was the wrist pin/bearing.
I put fresh gas in to see if it would actually fire--and it did. Unfortunately it was rattling like heck.
Soooooo....time to pull the top end and have a look at the damage. I figured I'd document the process here and share what I found. I welcome any input you guys would like to give during this process.
Here's the bike.
Thanks.
Bruce
sandblaster:
Hey Bruce, welcome to the best Kawi forum on the web.
There is more info, combined knowledge, and people who are willing to share then any other site out there.
Pop the top off that thing and lets have a look.
And while you have the top off, take a close look at the crank and lets see what all you may need.
Looks like you have a nice clean bike to start with.
Foxx4Beaver:
welcome brucifer....nice clean lookin 93.
do you plan on keeping it for a while?
brucifer:
Thanks for the warm welcome fellas. :-)
The bike looks better in the pics but it actually is in pretty decent condition as far as rust/corrosion etc. I bought some UFO plastics to replace the faded stuff currently on it.
I do plan on keeping it--as long as we get along. :-D
brucifer:
Okay, I removed the top end and it's worse than I imagined. :-(
With the head removed, it was revealed heavy scoring on the cylinder.
When I removed the cylinder, the source of the rattle presented itself--the rod big end. It has about 1/4 inch or better up and down play and it's trying to lock up as well.
The piston.
The intake manifold is all cracked.
Are these reeds stock?
When I was removing the cylinder, some leftover coolant poured directly into the crankcase so......
W
Navigation
[0] Message Index
[#] Next page
Go to full version