Maintenance & Technical > KX500 Original

The Next Rebirth!

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dirtball:
So I finally broke my '92 KX500 right, its not shifting correctly, and its time to split the cases and find out what is going on.  It had also been coming time for a fresh top end, she read 120PSI on the compression gauge before the descion to tear her down.  

So far I have noticed that my power valves were overclosing,  and I have a Stealthy flywheel weight installed that I did not know about when I bought the bike.  This thing is gonna SCREAM once its back together.  I also managed to find some crud in the pilot jet.  Hopefully she will idle again.


Question for those who have used a flywheel weight, how are they attached?
I noticed a series small hex head set screw s on the outside circumfrence, but did not have the right allen wrench to remove the set screws.  I belive these may hold the weight on, but there was also a secion on the outside in the center where it looks like a puller may have to be used.


This is the first bike I have had since I was about 15(I just turned 26), I got to ride it 5-6 times before the shift problem.   Running like a cripple, the power totally hooked me, I can't wait to get her working back to factory spec again!

Thanks for the insight on the flywheel weight in advance!


Travis

KXcam22:
Piece of cake to get it off.  It threads on in place of the flywheel nut and goes over your flywheel like a cover.  The setscrews around the outside help to secure it a bit.  To remove it, undo all the setcrews then turn it off in the same direction as your crank spins.  Mine had a small steel plate that bolted on the face (for removal only) that had a 3/8" square drive hole in it so you could turn it off with a ratchet.  You might be able to get a strap wrench over the outside or it would be an easy matter to build a removal plate out of some flatbar. Hope this helps. Cam.

dirtball:
The set screws are in there some kinda tight,  I twisted up a T-Handle allen key, I have a bad feeling the previous owner was a maniac on overtorquing things.  The headache is the engine is out of the bike and halfway apart already, Stopping the crank from turning during removal will be the interesting part.  Any Suggestions?  Any idea what size the threads are to put the removal plate on?  Are those by chance left handed threads?  I am not sure what direction the engine rotates.


Travis

KXcam22:
Dirt,
  Facing the flywheel the engine rotates CCW.  If I recall I think the threads on the removal plate are typical RH standard thread (non metric) since the flywheel is made in Oregon.  Soak the setscrews in liquid wrench or some other bolt loosener first.  If you phone steahly they can confirm. Cam.

dirtball:
Does anyone have a contact number for Stealthy.  I am not having much luck
finding info on them.


Thanks


Travis

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