KX Riders
Maintenance & Technical => KX500 Original => Topic started by: sandblaster on June 04, 2015, 12:47:13 PM
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http://www.oem-cycle.com/forum/viewtopic.php?f=41&t=1027&p=4080#p4080 (http://www.oem-cycle.com/forum/viewtopic.php?f=41&t=1027&p=4080#p4080)
Found some interesting damage..
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Interesting... Never seen such damage before...
Seen the seal spin (clutch side) on my old kx500 back in 93-94 sometime...
Welded and grinded back to size/alignment, but thats a different story...
New /used case is the Quick way to go..., but it is fixable in a mashineshop, so don't throw it away please :-)
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but it is fixable in a mashineshop, so don't throw it away please :-)
Never... I have several bad ones that I am saving for a rainy day :mrgreen:
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When we are done it will look like this one were started working on today..
(http://www.oem-cycle.com/forum/download/file.php?id=3325)
(http://www.oem-cycle.com/forum/download/file.php?id=3326)
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Thanks for the good info sandblaster
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When we are done it will look like this one were started working on today..
(http://www.oem-cycle.com/forum/download/file.php?id=3325)
(http://www.oem-cycle.com/forum/download/file.php?id=3326)
Sandblaster are them extra holes in the crank done by the crank people ?
89on cranks dont have alignment holes?
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Yep... After market... Thank you Pinsonnault Racing 8-)
Wossner rod which is a little hard to see in these pics.
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What % were they balanced at?, My cranks seem to have metal removed from opposite side, finding it hard to understand why the drill big holes like that?
eg
(http://i246.photobucket.com/albums/gg119/cr500-af/crankkxbalanced1.jpg)
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59%
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Crank half is done.
(http://www.oem-cycle.com/forum/download/file.php?id=3341)
The company I had repair it had to grind it undersize then plate it, then grind it to the finish size...
Perfect! 8-)
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does it hurt to have them ground so its more like a slip fit, throw some retaining compound on it when going together? make putting the halfs together so much easier.
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First, it is ground to cleanup, then, it is plated oversize so that when they grind it, they grind it to the factory finish size.
Just for grins I checked the fit and it is perfect.
Gotta like that :mrgreen:
The current cost is 75 USD to have one repaired but you have to have it pressed apart first..
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Is that at the place across they alley 'Blaster?
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Yep
But if you walk in the door you won't get it done for that price :wink:
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The case is at the plate shop along with the bearing for the correct interference fit.
Here's their main tank.
(http://www.oem-cycle.com/forum/download/file.php?id=3350)
The plater said the case had too be EXTREMELY clean before he would put it in his tank
(http://www.oem-cycle.com/forum/download/file.php?id=3351)
I think we did a ok job :lol:
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Man, that brings back memories. My dad owned a chrome shop when I was a kid, and I can still remember the smell of those chemicals. I don't know how those guys do it today. The EPA pretty much ran my dad's place out of business with all the new regulations.
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1.5 million in pollution controls, constant monitoring and compliance with all the codes.
The foreman spends more time filling out the papers then he does working on parts.
It's crazy..
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Off to Pinsonnault Racing for the full treatment...
(http://www.oem-cycle.com/forum/download/file.php?id=3352)
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Got my mouth watering...
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Welcome to our case lapping shop.
Notice how when we first start the edges are dark gray and the center is yellow?
That's because the outside edges are making contact but the inside of the cases are not.
Can you say Air Leak?
We knew you could!!! :D
(http://www.oem-cycle.com/forum/download/file.php?id=3422)
After 10 minutes on the lapping machine you can see that there is more dark grey...
But still there is that persistent yellow in the middle.
(http://www.oem-cycle.com/forum/download/file.php?id=3423)
After about 20-25 minutes total we are getting a nice consistent dark grey all the way around... Success!!
(http://www.oem-cycle.com/forum/download/file.php?id=3424)
Meet my lapping machine... His name is Jason :lol:
(http://www.oem-cycle.com/forum/download/file.php?id=3425)
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Enlarging and chamfering the main bearing oil passage for better lubrication..
(http://www.oem-cycle.com/forum/download/file.php?id=3426)
Now for some oil passage massaging at the porting table..
(http://www.oem-cycle.com/forum/download/file.php?id=3427)
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All new snap rings, bushings, and collars.
Clean too..
(http://www.oem-cycle.com/forum/download/file.php?id=3442)
Before
(http://www.oem-cycle.com/forum/download/file.php?id=3444)
After
(http://www.oem-cycle.com/forum/download/file.php?id=3445)
Before
(http://www.oem-cycle.com/forum/download/file.php?id=3446)
After
(http://www.oem-cycle.com/forum/download/file.php?id=3447)
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As if it weren't clean enough already...
(http://www.oem-cycle.com/forum/download/file.php?id=3457)
(http://www.oem-cycle.com/forum/download/file.php?id=3458)
Assembly has started
(http://www.oem-cycle.com/forum/download/file.php?id=3459)
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Next thing you know I'll have to wear a hair net and white gloves around the shop instead of what I usually wear...
(http://www.oem-cycle.com/forum/download/file.php?id=3460)
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When enlarge and chamfer the main bearing holes in the case. What size do you drill to? Thanks
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I'm curious about that too. I pulled out the 250 cases on the weekend to see what size the holes were, about 4mm, so I grabbed a lathe centre drill and counter sunk the tops of the holes then used a 6mm drill to open the holes up then using a die grinder chamfered the bottom of the holes to blend into the castings better.
What's the oil passage grinding being done?
Thanks
Luke
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Next thing you know I'll have to wear a hair net and white gloves around the shop instead of what I usually wear...
(http://www.oem-cycle.com/forum/download/file.php?id=3460)
LOL, you can make and sell food on the side while working on your motors. :-D
Ed
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When enlarge and chamfer the main bearing holes in the case. What size do you drill to? Thanks
I use a 6mm drill then a low speed countersink.
I only do this with the KX500 and some older KX250's.
The KX250's I forget what size I use but it is the same as the newer KX250 cases.
LOL, you can make and sell food on the side while working on your motors. :-D
Ed
Look below my right elbow.
You will see some Chef Merito Carne Asada seasoning :-D
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Thank You sir. for all the great advice and info.
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Thank Motorrad.
He has shared a wealth of info on this site and I recorded most of it :-o
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I would be carefull drilling that oil way much bigger as there is very little meat on the outer sides
I Would usually use a dremel to widen the area behind the main bearing and countersink the top
(http://i246.photobucket.com/albums/gg119/cr500-af/kx500%2088%20cases/SAM_0448_zps33f448d7.jpg)
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Your right, 6mm is the max we go.
We have been considering enlarging the outlet as your picture shows as well..
Thanks for sharing.
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(http://www.oem-cycle.com/forum/download/file.php?id=3465)
(http://www.oem-cycle.com/forum/download/file.php?id=3462)
(http://www.oem-cycle.com/forum/download/file.php?id=3463)
(http://www.oem-cycle.com/forum/download/file.php?id=3464)
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(http://www.oem-cycle.com/forum/download/file.php?id=3466)
(http://www.oem-cycle.com/forum/download/file.php?id=3467)
(http://www.oem-cycle.com/forum/download/file.php?id=3468)
(http://www.oem-cycle.com/forum/download/file.php?id=3469)
Getting closer
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Looking good.
Is that a team green top end?
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Is that a team green top end?
It was slightly modified when we received it from the customer.
We did the Team Green mods and a couple of Motorrad mods.
Nothing scary :-D
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(http://www.oem-cycle.com/forum/download/file.php?id=3466)
(http://www.oem-cycle.com/forum/download/file.php?id=3467)
(http://www.oem-cycle.com/forum/download/file.php?id=3468)
(http://www.oem-cycle.com/forum/download/file.php?id=3469)
Getting closer
(http://i2.wp.com/www.lorainekv.com/wp-content/uploads/2014/09/a99176f17f98d40c567bce80a2707a2090dddb5e93468bca673bcc1b69c4ecf8.jpg?resize=448%2C256)
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Done and ready to ship.
I hope the owner gives you all the love and RESPECT you deserve or, you'll break more then his heart :-D
(http://www.oem-cycle.com/forum/download/file.php?id=3472)
(http://www.oem-cycle.com/forum/download/file.php?id=3470)
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Thats beautiful Sandblaster, well done! Thats going to be one happy customer. :-)
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That's got to be like one of your kids leaving the house when they grow up. :-D
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Thanks guys.
I'm sure the owner will be very happy.
Now I have to get started on the next one :-o
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The motor is going to a very good home, mine.
I can't wait for it to show up.
I will say thanks for all the hard work and time you put into it.
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I'm a little jealous Singletrack, you're a lucky guy. Sandblaster made that dude look better than a new motor. I'm going to bet it will be fast as heck too. We'll need a ride report of course. 8-)