Maintenance & Technical > KX500 Original

02 KX 500 head gasket leak

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The Flyin Hawaiian:
I have a question about a external coolant leak on a 02 KX 500. I am probably swapping my old DR350/435S for my brother inlaws KX 500. I noticed that it has a external coolant leak around the head gasket when running. It has the optional thicker head gasket. I had this same problem on my old 88 KX 500 also. It doesnt seem to be getting into the cyl. Anybody else experiance this? Cant wait to get it!

stewart:
toss the fiber thick gasket in trash and lap the head to be sure its flat put on a cometic steel gasket and some gray sealer around the water passeges and that will solve problem

BDI:
If you want it to leak some more then ignore what Stewart said. :wink:

KXcam22:
I 3rd what Stewart said. Lap Lap Lap. Easy and works great.  I start by lightly lapping the head and barrel surfaces separately using #400 emery cloth taped to glass or a super flat steel plate. Then lap them to each other using valve grinding compound.  You will have to pull the head studs but don't skip doing the barrel because of it. The trick with lapping is to go slow with a twisting motion and inspect the surface frequently. You will watch the dull grey area grow as you lap.  Hope this helps. Cam.

ps if anyone has other methods I am all ears.

mdw471:
Great Idea!!

After you have lapped the head and barrel the first time, does it stay flat even after use? Or do you redo it everytime you change the piston?

Does the lappong correct a manufacturing short coming or does heat cycling the engine cause it to 'warp' out?!?

Mark

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