Maintenance & Technical > KX500 Original

Worn through SIDECASE!!

<< < (2/3) > >>

NZ500:
I had the same problem with my '90. It had been welded up before but rather than prevent it happening again the last owner kept using the same chain/sprockets.

When I had the cases apart I drilled and tapped a piece of mild steel plate (about 20 or 25mm thick), bolted the case to it and built the whole area up with weld. Then lapped the cases on a cast iron surface plate. To prevent it happening again and continue using the (bulky) O-ring chain and sprockets which were nearly new I managed to find a new sprocket that is much thicker/same splines and machined out the difference so it offsets the sprocket away from the motor (80s DR 650 I think it was). I have a jig that bolts to the three holes in those sprockets for machining them. They are very hard though. My rear wheel spacers were miles off already so had to make new ones any way. I don't use anything smaller than a 14 tooth on the front. Might not be any use to you but someone else might find it useful.

Depending on how bad it is you might be able to put some copper/bronze under the hole to build that area up. Having a hole would be more likely to cause distortion though and you'd definately want it bolted to something flat. Letting it cool between welding parts might help too. The cast iron inserts are a bit of a pain but I managed to build up weld over top of them.

DoldGuy:

--- Quote from: cattamer on December 21, 2011, 11:04:44 PM ---Hello fellow riders.My 1993 500 has a hole worn in the case behind the countershaft sprocket.In replacing the cases? (all I have seen new  come in pairs)should I take a chance on one from E-bay or just bite the bullet and go back completely new givin the age?I am going to check everything once I get in.

--- End quote ---

Post some pictures for Larry to see.......He is very gifted & may save you a bunch of $$$$$$
DoldGuy

The Flyin Hawaiian:
There was a article a while back in Dirt Rider where they rebuilt a older CRF250 and it had the same issue. They sent it somewhere and had it welded and remachined at a pretty reasonable price. Im pretty sure it was earlier this year.

cattamer:
Upon further inspection,it has to be the seal and o-ring?The splines on the shaft are worn badly,and it has caused the sprocket to wobble and rub the case severly,but not all the way through.

cattamer:
I will replace the shaft,and anything else worn inside.I dont know alot about this bike,and the guy I bought it from didn't take very good care of it.Do you think I should replace the crank bearings and seals,while i'm inside.I am gonna have the cylinder checked and new piston and rings. I was told that the case halves are a matching pair and therefore sold in pairs.Is this true?

Navigation

[0] Message Index

[#] Next page

[*] Previous page