Maintenance & Technical > KX500 Original
Catastropic Top End Damage - Opinions Appreciated
jcm3:
So, I went out for a weekend riding trip with a good buddy, and we were both riding KX500's that we recently bought. I found a 2000 KX500 in great condition, and spent the few weeks prior to the trip fixing little stuff that needed it. I did the typical maintenance stuff: flushed the brake fluid and coolant, changed the oil, greased all of the bearings except the steering stem bearings, put a new rear tire on it. safety wired some things, lubed the clutch cable, cleaned the air filter, checked spokes, etc. i also checked the compression, and it was a bit low, but in the middle of the range at about 130psi. I planned on replacing the top end after that trip, as I just didn't have time before. What is one more ride on a 15 year old, clean bike?
We did some light trail riding on Friday, and Saturday we hit up the Hollister GP track for a few motos on an open public track day. On my third session (they were about 10 minute sessions, as it's the first time I had ridden in about two years), it made sounds that you don't ever want to hear and locked up tight. I assumed I seized it until I pulled the pipe.
When I pulled the pipe, I was greeted with nothing in sight. No piston, connecting rod, etc. Big ouch. The bottom of the piston grenaded, and the top half with the rings is still in place up top. It hit the spark plug and put a few mild knicks in the head, but nothing big. I'm more worried about the cylinder and the bottom end. It didn't seize, as I could push the piston down with my finger.
I do see some damage to the cylinder, but won't know for sure until I pull it apart. I'm hoping it is repairable, and also hoping the cases are not damaged by the shrapnel until it locked up tight. I know that I'll definitely need:
- top end rebuild
- bottom end rebuild
- cylinder repair and re-plate
I was thinking about sending the entire motor off to Pinsonnaultracing for their $1450 total rebuild, knowing that it will cost extra to have the cylinder repaired. Has anyone dealt with them, and what kind of work do they do? Their repair includes just about everything except transmission work - http://pinsonnaultracing.com/KX500CompleteRebuild.aspx
Should I just bring the bottom end somewhere to have it rebuilt, have the cylinder repaired, and put it back together myself?
What do typical cylinder repair cost, and would it make more sense to just buy a new jug?
I don't know what I don't know here, but am very mechanically inclined, and have rebuilt the top end on about 5-8 different two strokes and my old YZ426 four stroke. So, I'm not intimidated by the work.
Thanks for anyone's opinion and input. I have a feeling that some of the input will prompt more questions. :-D
alward25:
Sending it to Todd to have it gone through will be a sure bet everything will be done right and ready to drop in. Great guy to deal with. You would not be saving much by doing it yourself.
jcm3:
--- Quote from: alward25 on June 23, 2014, 08:21:54 AM ---Sending it to Todd to have it gone through will be a sure bet everything will be done right and ready to drop in. Great guy to deal with. You would not be saving much by doing it yourself.
--- End quote ---
Great to hear, thanks.
I agree about not saving much doing it myself or piecemeal. I just called my dealer to find out how much they'd charge to do just a bottom end rebuild, and they said $1400-1500 just for that. Easy decision.
I'm just hoping that I don't run into too much extra cost. Cases are $500-ish, as is a new jug. We'll see, I guess!
Foxx4Beaver:
--- Quote from: jcm3 on June 23, 2014, 07:32:02 AM ---I was thinking about sending the entire motor off to Pinsonnaultracing for their $1450 total rebuild, knowing that it will cost extra to have the cylinder repaired. Has anyone dealt with them, and what kind of work do they do? Their repair includes just about everything except transmission work - http://pinsonnaultracing.com/KX500CompleteRebuild.aspx
--- End quote ---
my motor is partially Pinsonnault-ed...and I can say I'm MORE than happy with the end results as far as performance is concerned.
jcm3:
--- Quote from: Foxx4Beaver on June 23, 2014, 09:53:09 AM ---
--- Quote from: jcm3 on June 23, 2014, 07:32:02 AM ---I was thinking about sending the entire motor off to Pinsonnaultracing for their $1450 total rebuild, knowing that it will cost extra to have the cylinder repaired. Has anyone dealt with them, and what kind of work do they do? Their repair includes just about everything except transmission work - http://pinsonnaultracing.com/KX500CompleteRebuild.aspx
--- End quote ---
my motor is partially Pinsonnault-ed...and I can say I'm MORE than happy with the end results as far as performance is concerned.
--- End quote ---
Awesome, it's great to hear good reviews. I hoped I would. I need to get my butt to work on pulling the engine out and getting it to him. The downside will be the cost, the upside will be that it's fresh from top to bottom.
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