Maintenance & Technical > KX500 Original

Engine Tear Down

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blueoval:
I am going to tear the engine down and replace the crank seals and check/measure clearances/inspect/etc the engine.  Do you guys tear the engine partway down while it's in the bike like the Clymer manual states - removing the cylinder head, removing the cylinder, piston, clutch, etc.  Or do you take the whole engine out of the chassis then tear it down?  thx ted

KXcam22:
Ted,
  I like to remove the whole engine first.  That way it is easier to give the exterior of the engine a good cleaning in all the nooks and crannys before tearing it down. Cam.

Dutch-K5 Fan:
These things can be done in the frame.
I agree with cam to take the engine out. It doesn't take much more time and works alot bettter.

Dutchie

blueoval:
Thank you Dutch and Cam for the advice.  I will start tonight. 

Friar-Tuck:

  BlueOval,
 Like the other guys said, getting the engine out and on the bench will keep "stuff" from finding it's way into your crankcase, and working on the bench is easier on you. :wink:
   Making a small "box" to hold the engine relatively upright is handy.

   There will be a few specialty type items you will need to get the flywheel off,
 
  http://www.rockymountainatvmc.com/productDetail.do?navType=type&webTypeId=203&navTitle=Engine&webCatId=17&prodFamilyId=17329#vehicleSelect
 
 and something to Split the Cases.
 http://www.rockymountainatvmc.com/productDetail.do?navType=type&webTypeId=140&navTitle=Tools%2FShop&webCatId=22&prodFamilyId=17167

 Several guys have made their own tools to separate the cases, and improvised.
   An impact will spin off the clutch nut, and either a gear jam,

http://www.rockymountainatvmc.com/productDetail.do?navType=type&webTypeId=140&navTitle=Tools%2FShop&webCatId=22&prodFamilyId=22841

   Or something to hold the clutch/crank
 http://www.rockymountainatvmc.com/productDetail.do?navType=type&webTypeId=140&navTitle=Tools%2FShop&webCatId=22&prodFamilyId=18289
   I have to admit I have used a penny (metal softer than gear) to jam  gears to be able to check  the torque  on things in the past.   :oops:
   
  Gaskets,seals and consumables will run around $110.00
 The tools you either build or buy can be used on your other bikes. 
   
 I know it's discouraging to have  just gotten a bike and then have to go through all this,
     Hang in there, when you get this old girl up to snuff you will be able to blow the handguards off 90% of the $8,000.00 dirt bikes you come up against in the field.   :-D

   Hopefully some of the other guys will have some more input.

 You have made a good decision, lots of folks these days don't want to make the hard choices.
    Tuck\o/

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