KX Riders
Maintenance & Technical => KX500 Original => Topic started by: brucifer on April 11, 2014, 01:37:38 AM
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Hey guys, new KX500 owner here. I've been riding since I was 4 years old--mainly four-strokes with the occasional two-stroke thrown in. I'm now 48.
I just sold an '84 CR500 so I'm not a noob to 500cc two-strokes but I am to the mighty KX500.
I had posted a wanted ad on CL for a dirt bike project and was offered this bike. The PO had purchased it from a neighbor who pretty much didn't know the meaning of the word maintenance. The gentleman I purchased it from gave me a list of everything he did to it and what he thought needed attention. The bike had not run since the PO bought it from his neighbor but I was assured it did run.
When it was delivered to me, I checked it over and discovered it had decent compression but something felt "loose" when I kicked it over. I got it on compression and grabbed the kickstarter with my hand and kinda moved it against compression and relaxed, against compression, relaxed a few times and could feel play and could hear a muted kind of a "clank" in the top end. The first thing I thought of was the wrist pin/bearing.
I put fresh gas in to see if it would actually fire--and it did. Unfortunately it was rattling like heck.
Soooooo....time to pull the top end and have a look at the damage. I figured I'd document the process here and share what I found. I welcome any input you guys would like to give during this process.
Here's the bike.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02479_zpsa425a047.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02479_zpsa425a047.jpg.html)
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02480_zps66269eec.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02480_zps66269eec.jpg.html)
Thanks.
Bruce
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Hey Bruce, welcome to the best Kawi forum on the web.
There is more info, combined knowledge, and people who are willing to share then any other site out there.
Pop the top off that thing and lets have a look.
And while you have the top off, take a close look at the crank and lets see what all you may need.
Looks like you have a nice clean bike to start with.
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welcome brucifer....nice clean lookin 93.
do you plan on keeping it for a while?
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Thanks for the warm welcome fellas. :-)
The bike looks better in the pics but it actually is in pretty decent condition as far as rust/corrosion etc. I bought some UFO plastics to replace the faded stuff currently on it.
I do plan on keeping it--as long as we get along. :-D
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Okay, I removed the top end and it's worse than I imagined. :-(
With the head removed, it was revealed heavy scoring on the cylinder.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02490_zps73989a2a.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02490_zps73989a2a.jpg.html)
When I removed the cylinder, the source of the rattle presented itself--the rod big end. It has about 1/4 inch or better up and down play and it's trying to lock up as well.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02492_zpsa35314d7.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02492_zpsa35314d7.jpg.html)
The piston.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02491_zps3c31ca89.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02491_zps3c31ca89.jpg.html)
The intake manifold is all cracked.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02493_zps694349f4.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02493_zps694349f4.jpg.html)
Are these reeds stock?
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02494_zps3248ee8a.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02494_zps3248ee8a.jpg.html)
When I was removing the cylinder, some leftover coolant poured directly into the crankcase so......
W(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02495_zps2e8c1782.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02495_zps2e8c1782.jpg.html)
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yup, that's a bummer!...with the crank being that shot, you can only assume the rest of the motor is screaming for some TLC.
Since you said you plan on keeping it...might as well do it right and drop $1500 right off the top, and replace all the bearings/seals, new OEM crank, re-plate cylinder and top-end...and then any clutch or tranny issues that need attention will cost more...but it'll be worth it!
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+1...
I know it's a bummer to see your engine like this but it's all rebuildable.
Could you post some pics of the bottom of the cylinder and also looking into the intake area?
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Yeah guys, I'm gonna go completely through it. I'm a sucker for orphaned and abused bikes. I take joy in bringing them back to health--and losing money in the process. :-D
All kidding aside, I really do enjoy this. It's relaxing to me and quite satisfying to experience the end result.
I just went through this with a plated '95 XR600. I did a frame up resto-mod and sunk way more money into it than it will ever be worth. lol. But in the end it was worth it to me and I'm very happy with the result.
Here's a kinda fuzzy pic of it.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02410_zpscda2b46e.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02410_zpscda2b46e.jpg.html)
And a not so fuzzy pic.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02456_zpsbf766844.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02456_zpsbf766844.jpg.html)
sandblaster-I'll get some pics of the cylinder in the next day or two.
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Sweet.
Thanks!
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+1...
I know it's a bummer to see your engine like this but it's all rebuildable.
Could you post some pics of the bottom of the cylinder and also looking into the intake area?
Here's some pics.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02503_zpsbffeeccb.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02503_zpsbffeeccb.jpg.html)
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02504_zps2a8e7863.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02504_zps2a8e7863.jpg.html)
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02505_zps1df44878.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02505_zps1df44878.jpg.html)
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Hey Bruce, welcome to the best Kawi forum on the web.
There is more info, combined knowledge, and people who are willing to share then any other site out there.
Pop the top off that thing and lets have a look.
And while you have the top off, take a close look at the crank and lets see what all you may need.
Looks like you have a nice clean bike to start with.
I just luv those blue forks like I need some :lol:
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Appears to be completely stock...
A little time with a dremel goes a long way :-D
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thought my eyes were playin tricks on me...almost looks sleeved.
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thought my eyes were playin tricks on me...almost looks sleeved.
That is sleeved.
From the pics of the piston & cylinder, I think the head gasket was leaking (HATE those fiber head gaskets) & washed down the cylinder (no oil between piston/cylinder) as the scuffing in the cylinder is at the exhaust port (just my $.02).
I have seen a sleeved cylinder, with no matching of the ports, and still can not understand how it runs so well, as there has to be at least 2mm mismatch in the ports, but it runs very well.
Good thing with the sleeved cylinder it can be bored for not to much monies :-D , add a piston kit, rod kit, crank bearings / seals & a good set of gaskets will hopefully get you riding the K5 :-D , but I would positively make sure BOTH cylinder & head surfaces are totally flat. Had a friend with a K5 that was sleeved, kept having head gasket issues & it was just a very small area of the sleeve raised causing the problem.
DoldGuy
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thought my eyes were playin tricks on me...almost looks sleeved.
That is sleeved.
I know, I was being sarcastic...you can clearly see the difference in color.
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thought my eyes were playin tricks on me...almost looks sleeved.
That is sleeved.
I know, I was being sarcastic...you can clearly see the difference in color.
My eyes DO play tricks on me
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thought my eyes were playin tricks on me...almost looks sleeved.
That is sleeved.
I know, I was being sarcastic...you can clearly see the difference in color.
My eyes DO play tricks on me
hehe...it's the vodka that plays tricks on my eyes :-D
I had a 93 KX250 that I had sleeved back in 95 by Kustom Kraft...and I started using coolant like crazy, adding some every ride....and it was the sleeve sticking up ever so slightly over the cylinder.
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Finally got the parts ordered and will start the disassembly and rebuild shortly........hopefully. :-D
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I rebuilt a 1993 KX 500. It was a fun project, but got a little pricey, but it was well worth it in the end.
When I tore the motor down, I found out that the chain skipped and hit the case where the clutch pull is located and cracked it. I was able to obtain new cases from a 2004 model. After all the bearings and seals were purchased for the bottom end, I had a friend who used to wrench for Team Green assemble it for me. He modified the third gear for me, ( I still don't know what that means) and put it all together for me. I sent the cylinder out to Mellinium to be replated. While assembling the motor, my buddy did a modification to the KIPS valve system. He also rebuilt my forks and shock for me as well.
The bike is an awesome ride for being 21 years old. It starts up easily and runs perfect. A few months ago, I acquired a 2002 rolling chassis and put the motor in it. Everything is the same, but now its a 2002 KX 500.
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Modified the third gear?
I would be greatly interested in what he modified...
If you find out, let us know as I am certain there is more then a few of us interested to know.
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Modified the third gear?
I would be greatly interested in what he modified...
If you find out, let us know as I am certain there is more then a few of us interested to know.
Undercut gear dogs? I understand K5s are hard on 3r gear. Undercutting that pair would certainly keep them together better. That is an obvious one tho. Maybe there are some Team Green secrets in there...
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Modified the third gear?
I would be greatly interested in what he modified...
If you find out, let us know as I am certain there is more then a few of us interested to know.
Undercut gear dogs? I understand K5s are hard on 3r gear.
yeah, sounds about right....there's a thread or two on here about undercutting.
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Hey mate,
I have a 93 engine and the best thing I ever did was change out the gear shifter to a later model one. Mine had the 11mm spline and I changed it to the 13 froma 2000 model. It allows more options with shifter changes as modern KX F use the 13mm. It is also hard to get alloy shifters for the 93 in my experience.
TSF
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Finally got around to pulling it the rest of the way apart. The frame, subframe and peg mount are going to the powdercoater.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02517_zps05e9dc5c.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02517_zps05e9dc5c.jpg.html)
This is probably going to be a drawn out process so bear with me. :|
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I'm going on my 3rd year for my beer can build so don't feel bad.. :-o
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I'm going on my 3rd year for my beer can build so don't feel bad.. :-o
Thanks sandblaster but I've got you beat on the procrastinate scale. I started my '84 Honda XL600R project in 2007 and it's STILL not finished. lol. Hopefully the KX will be finished much sooner. :-D
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I'm going on my 3rd year for my beer can build so don't feel bad.. :-o
Thanks sandblaster but I've got you beat on the procrastinate scale. I started my '84 Honda XL600R project in 2007 and it's STILL not finished. lol. Hopefully the KX will be finished much sooner. :-D
:-D
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I knew it was going to take a while to build this thing but it's taking longer than even I had figured. :lol:
I am working on four other bikes besides this one though, so time and money is spread extremely thin between them all. Doing it this way, it seems like I'm not making progress on ANY of them but I am--however incrementally. :|
Frame pieces done and forks rebuilt.
(http://i122.photobucket.com/albums/o260/wheelinthesky/DSC02651_zpsyqfzzw3r.jpg) (http://s122.photobucket.com/user/wheelinthesky/media/DSC02651_zpsyqfzzw3r.jpg.html)
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Yeah & I thought I needed to change my name to slow build. Been on a beer can cr5 & a kx5 steelie for 3 years simultaneously. Sucks cause I'm left with a 250 to ride & no big bore :cry:.
That green looks sweet, you're getting there for sure powder coat on the frame always seems like the downward side as the new & shinny is a great motivator :mrgreen: