Maintenance & Technical > KX500 Original

some bottom end questions

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tschisi:
Hi!

I just started to dismantle my bottom end to replace the main bearings and seals.
As suspected, the first questions are raised before the engine is even split.  :roll:
I would be glad if you could guide me a little bit through the process, this is my first bottom end.

- Would you replace parts routinely or just the main bearings and seals?
What about the other bearings? Output shaft? I think i have read that standard bearings fit?

- How much clearance is ok for the gearwheels?
Can the ones without pitting stay?

- My clutch basket has rough notches from the clutch discs, i think they are too deep for filing?
http://img7.imageshack.us/i/bottomend007.jpg/
I also have notches on the hub, but this ones can hardly be felt with the fingernail.
http://img97.imageshack.us/i/bottomend001.jpg/

- What about putting thread inserts to the cases, such as helicoil or timesert?
I don?t want to re-assamble everything an then veer a screw.
Do you think there is enough material for drilling and for the inserts?

thx guys!

jonny500:
if you split the cases you should do all you can. my personal opinion is replace all seals and bearings and every thing that is out of spec. there is a good thread on here where we helped some one else out i will see if i can find it

jonny500:
ok i found it. http://www.kxriders.com/forums/index.php/topic,7974.msg61265.html#msg61265
its for a 250 but most info is usfull or all. read it from start to finish and you should get a good idea of what you need to do. then of course ask all the question you need to

tschisi:
nice link, thanks!
Although it has made me afraid of a worn crankshaft...  :-(

What do you think about my clutch basket?
This could become my biggest problem.

jonny500:
i am not a fan of filing baskets, if you must you have to take the same amount of each finger or there will be uneven stress on the plates. i have known plates to break for this reason. you could spend thousands on it if you want it depends on you budget. if the clutch was working fine then leave it until it starts to misbehave as its an easy job with the motor in the bike.

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