KX Riders

Maintenance & Technical => KX500 Original => Topic started by: sandblaster on June 04, 2015, 12:47:13 PM

Title: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 04, 2015, 12:47:13 PM
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..
Title: Re: 91 kx500 engine disassembly and inspection
Post by: MRDART on June 04, 2015, 07:10:46 PM
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 :-)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 04, 2015, 07:45:35 PM
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:
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 09, 2015, 01:32:41 PM
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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: chaelvick on June 09, 2015, 02:45:28 PM
Thanks for the good info sandblaster
Title: Re: 91 kx500 engine disassembly and inspection
Post by: dave916 on June 10, 2015, 03:35:14 AM
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?
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 10, 2015, 03:37:37 AM
Yep... After market... Thank you Pinsonnault Racing  8-)
Wossner rod which is a little hard to see in these pics.
Title: Re: 91 kx500 engine disassembly and inspection
Post by: dave916 on June 10, 2015, 06:08:09 AM
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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 10, 2015, 12:36:01 PM
59%
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 16, 2015, 12:28:07 PM
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-)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: edgar_kx3 on June 16, 2015, 01:24:33 PM
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.
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 16, 2015, 01:39:45 PM
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..
Title: Re: 91 kx500 engine disassembly and inspection
Post by: alward25 on June 17, 2015, 01:57:07 AM
Is that at the place across they alley 'Blaster?
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 17, 2015, 02:27:46 AM
Yep
But if you walk in the door you won't get it done for that price  :wink:
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 24, 2015, 07:56:33 PM
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:
Title: Re: 91 kx500 engine disassembly and inspection
Post by: umberto on June 25, 2015, 03:39:23 AM
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.
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 25, 2015, 07:24:30 AM
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..
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on June 25, 2015, 09:24:50 AM
Off to Pinsonnault Racing for the full treatment...

(http://www.oem-cycle.com/forum/download/file.php?id=3352)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: Bigbodybiker on June 27, 2015, 07:56:24 PM
Got my mouth watering...
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 10, 2015, 02:29:20 PM
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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 10, 2015, 02:30:17 PM
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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 13, 2015, 01:27:24 PM
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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 18, 2015, 03:06:02 PM
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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 18, 2015, 03:14:39 PM
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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: cmotodad on August 18, 2015, 06:29:22 PM
When enlarge and chamfer the main bearing holes in the case. What size do you drill to? Thanks
Title: Re: 91 kx500 engine disassembly and inspection
Post by: LukeG on August 18, 2015, 08:31:05 PM
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
Title: Re: 91 kx500 engine disassembly and inspection
Post by: ecdeyzel on August 18, 2015, 09:55:42 PM
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
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 19, 2015, 02:48:59 AM
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
Title: Re: 91 kx500 engine disassembly and inspection
Post by: cmotodad on August 19, 2015, 02:57:49 AM
Thank You sir. for all the great advice and info.
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 19, 2015, 03:01:56 AM
Thank Motorrad.
He has shared a wealth of info on this site and I recorded most of it  :-o
Title: Re: 91 kx500 engine disassembly and inspection
Post by: dave916 on August 19, 2015, 05:32:00 AM

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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 19, 2015, 05:35:43 AM
Your right, 6mm is the max we go.
We have been considering enlarging the outlet as your picture shows as well..
Thanks for sharing.
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 19, 2015, 01:40:25 PM
(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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 19, 2015, 01:41:41 PM
(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
Title: Re: 91 kx500 engine disassembly and inspection
Post by: dave916 on August 19, 2015, 09:35:38 PM
Looking  good.
Is that a team green top end?   
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 20, 2015, 02:28:46 AM
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
Title: Re: 91 kx500 engine disassembly and inspection
Post by: ecdeyzel on August 20, 2015, 02:35:49 AM
(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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 20, 2015, 10:48:16 AM
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)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: ecdeyzel on August 20, 2015, 06:53:44 PM
Thats beautiful Sandblaster, well done! Thats going to be one happy customer.  :-)
Title: Re: 91 kx500 engine disassembly and inspection
Post by: umberto on August 21, 2015, 03:38:11 AM
That's got to be like one of your kids leaving the house when they grow up.   :-D
Title: Re: 91 kx500 engine disassembly and inspection
Post by: sandblaster on August 21, 2015, 04:42:15 AM
Thanks guys.
I'm sure the owner will be very happy.
Now I have to get started on the next one  :-o
Title: Re: 91 kx500 engine disassembly and inspection
Post by: Singletrack on August 21, 2015, 06:20:07 AM
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.
Title: Re: 91 kx500 engine disassembly and inspection
Post by: umberto on August 21, 2015, 08:45:30 AM
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-)