Maintenance & Technical > KX500 Original

KX500 Cylinder removal

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bigtwin100:
I need to replace a base gasket on my 91 KX500. Top end is pretty fresh from the PO ( compression very good and piston/cylinder look almost new thru the exhaust port) and want to pull the cylinder with the head still on. Do I have to completely disassemble the KIPS or can I take the cylinder off with most of it intact?

Magnus:
The kips can stay in there, you actually need to take the cylinder off to get them out. Just remove the cover over the actuator arm and that should be it..

I don't think it is possible to take the cylinder off without removing the head though, at least it would very tight under the frame...

Polar-Bus:

--- Quote from: bigtwin100 on May 15, 2011, 04:43:33 PM ---I need to replace a base gasket on my 91 KX500. Top end is pretty fresh from the PO ( compression very good and piston/cylinder look almost new thru the exhaust port) and want to pull the cylinder with the head still on. Do I have to completely disassemble the KIPS or can I take the cylinder off with most of it intact?

--- End quote ---

Head has to come off first. There won't be enough room to slide the head/cylinder assembly off the piston assembly before hitting the frame.

bigtwin100:
I read on here it can be done without the head coming off but no biggie if I have to. I have a very small oil leak at the front base on the throttle side. Pretty small but it's bothering me. It seems to go away when the engine get's warm. The plug is nice and tan and it runs very well so I don't think it's an air leak

Polar-Bus:

--- Quote from: bigtwin100 on May 16, 2011, 01:28:44 AM ---I read on here it can be done without the head coming off but no biggie if I have to. I have a very small oil leak at the front base on the throttle side. Pretty small but it's bothering me. It seems to go away when the engine get's warm. The plug is nice and tan and it runs very well so I don't think it's an air leak

--- End quote ---

You shouldnt have "oil" leaking out of the base gasket, if anything you could be leaking some antifreeze. I could be wrong about the head having to come off first, but i'm almost positive the head hits the frame.

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