Maintenance & Technical > KX500 Original

First Top End rebuild - Need advice - Pics included

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BlackHills:
I am tearing down the top end on my 2001 kx 500 for the first time.  I have owned the bike for 2 years.  I know that I should be doing this more often anyway, but the bike was running so great I didn't want to screw it up. 

Anyway my bike has enough broken parts and the cold starting was getting so bad that I knew it was about time.  I tore the bike apart yesterday and found a few things that need to be fixed: aftermarket reed valves cracked, broken support on radiator, etc.  I new from the previous owner that the cylinder had been sleaved so I expected that, but I didn't expect the amount of metal removal that was done on the intake ports.

I found a couple of small cracks in the "normal" locations on the intake ports, but they don't appear to be cracked all the way through.  My problem is that I really can't afford to put more money into this bike so I wanted opinions on the pictures I took and what you think should/can be done.

Cylinder Walls:







Intake Ports:





Piston:







Also, I am having serious problems removing the allen bolt that holds the KIPS in place.  I am using so much force that I figure I am going to either break the allen wrench or strip the bolt.  Anyone have any advice?

Their is also an issue with the amount of crap in the exhaust ports.  Is this normal?





I can take more pictures of different areas, and of more detail if needed.  I just want to make sure I get this back running and it doesn't self destruct on me in a month.

stewart:
the cracks i see are from running a sleave in a cylinder not meant for a sleeve .. change to belray h1r oil at 50.to1 to clean up exhast port and be sure to use a wiesco forged piston to prevent future problems

BDI:
I ran a sleeved cylinder with all the same cracks that yours has for eight or nine years with out problem one. I always imagined the top of the cylinder blowing off the bottom but it never happend unfortutunately, that would have been one cool blow up.  :evil: :lol: :lol:

kaw rider:
has long you don't have this problem your ok.

BlackHills:
Thanks guys.  I don't think the cracks are that bad so I am hoping to put it back together the way it is.  I have a Wiseco top end kit that should be here in a couple of days (with piston).

Now a couple of follow-up questions.  How do I clean up the inside of the cylinder?  Not the cylinder walls themselves, but all the ports and areas with all the buildup.  Also what is the best way to clean up bolts and nuts that need a little TLC?

So far I have been cleaning up the outside of the engine with oven cleaner to get rid of the gunk (I had a big crack in my exhaust and a bunch of spooge all over my engine as a result).  For the bolts I was planning on soaking them in gas, diesel or kerosene then cleaning them with a wire brush or an attachment on a dremel.  I would like to get my bike looking somewhat presentable and serviceable again instead of just the hillclimbing beast that it is  :-D.

Anyone have any special tips or advice on cleaning up all the ports on the cylinder and bolts?

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