Maintenance & Technical > KX500 Original

Piston and Porting Questions

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BigGreenMachine:
The rust is my fault, cleanup and never got those little ports when I wiped it off with some oil.

How hard is it to convert the old pre 89 motor to 89-04 cylinder/PV setup?

don46:
Not an issue at all, you need cylinder head and kips. The pre- 89 had a larger pin for the actuation rod, so it needs to probably be replaced but the inner parts are the same, the clutch cover would work all the way to an 04. The only downside is the pre 89 has bigger ports and IMO they flow better.

BigGreenMachine:
Well say if I had the complete cylinder and head assembly from an 89-04 500, what would have to happen to make it work on my 88?

Just one more hole drilled in the case to accept the extra powervalve??

EDIT*** Yes, from the looks of my manual and cylinder it'll just be a matter of placing the hole for the extra PV.

I would rather buy an older used cylinder to have replated. Hoping to get this 5 buttoned up again soon. Powerwheelies in 5th are great! Never riding a 250 again.

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