Maintenance & Technical > KX500 Original

Need some help..

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kawi4ever:
Hi I have a 2003 KX500, just had the cylinder re-plated and the top resurfaced(due to warpage),also had the head re-surfaced also. While I had it apart i did crank seals and bearings and covered all the simple stuff that everyone always forgets, I also made all the intake port edges knife shaped, also bottom of transfer ports knife edged, So the problem I have is now when I ride the engine loads up at 1/4 to 1/2 throttle all the time now, I can not ride in the trails anymore because it loads up too much, I have dropped all the way down to a 50 pilot and that helped but still is bad, tried some C-12 race fuel today and that made it soo bad it would not idle, Is this fixable with a proper complete port-job and have the head properly re-shaped?  I an trying to use this cylinder before I order a new kawi cylinder.. Thanks for the help. ERIC

dave916:
i cant see how the slight porting [knife edgeing ] would effect the running this badly, sounds like u might have a problem related  to the full engine build , a leakdown test would be your first step before  u start taking the motor apart and spend cash ,   
whats the simple stuff that everone forgets :-D

Motorrad:
Check float level

dave916:
is the bike running rich or lean???   rich=smoke
i would not go making too many  adjustments to compensate for some other problem (ie jetting)
unlikly your float level would suddenly go out of adjustment but i have seen a bit of fuel line rubber get traped under float needle valve, [after the carb been removed]
dirt in the choke circuit is another reason for running rich, a slight bit of dirt can keep the choke plunger slighted opened

kawi4ever:
I have set float height it is correct, carb is clean, also the other thing i did change with the engine build is I put a set of V-Force 3 reeds in.. now what got me with the v-force is there was no tension on the reeds at all, I did the water test like stewart said from my old Rad-Valve to the new V-Force and the rad valve took 45sec to completely drain now the v-force brand new took about 7sec to drain??? Am I overlooking something as simple as a defective reed valve??

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