KX Riders

Commercially available service offered by members of KXRiders. => OEM-CYCLE => Topic started by: sandblaster on December 13, 2015, 02:30:13 AM

Title: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on December 13, 2015, 02:30:13 AM: This was a interesting engine that came to us.
The base of the cylinder was machined .040", the squish on the head was .045", the timing was retarded, and the boost ports were hogged out.
Someone was looking for some more torque :-o
But this customer want's HP and some more top end so we aim to please... 8-)

(http://www.oem-cycle.com/forum/download/file.php?id=3807)

(http://www.oem-cycle.com/forum/download/file.php?id=3808)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on December 13, 2015, 02:32:08 AM: Parts come to us like this..

(http://www.oem-cycle.com/forum/download/file.php?id=3809)

But they go back out more like this...

(http://www.oem-cycle.com/forum/download/file.php?id=3811)

(http://www.oem-cycle.com/forum/download/file.php?id=3810)

Ordered the rod Friday.
We will wait for it to get here then polish it.
Then we will send it out for balancing, and rebuilding.
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: DoldGuy on December 13, 2015, 02:13:16 PM: Not to sound retarded, but didn't you mean advanced.... :roll:?
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on December 13, 2015, 03:02:21 PM: Yep, my error... again :lol:
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on January 14, 2016, 02:57:02 PM: Balanced and ready for assembly.

(http://www.oem-cycle.com/forum/download/file.php?id=3843)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: alward25 on January 14, 2016, 04:55:47 PM: Looking good! :-D
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on January 14, 2016, 05:43:51 PM: I hope all those holes are correct :-D
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 15, 2016, 02:17:04 PM: Case lapping, You guys know the drill :roll:

Remove the junk

(http://www.oem-cycle.com/forum/download/file.php?id=3886)

Hold the right case down..

(http://www.oem-cycle.com/forum/download/file.php?id=3888)

Use this stuff (Thanks Motorrad)

(http://www.oem-cycle.com/forum/download/file.php?id=3889)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 15, 2016, 02:18:22 PM: This is the typical trouble area for KX500's... Note where the dark grey is around the edges of the cases.
Then look at the yellow area.
The yellow area means that the cases have a gap there.

(http://www.oem-cycle.com/forum/download/file.php?id=3891)

rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl...

(http://www.oem-cycle.com/forum/download/file.php?id=3892)

Now they are dark grey all around which means they are ready for clean up, porting, and repair,,
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 16, 2016, 04:37:11 PM: (http://www.oem-cycle.com/forum/download/file.php?id=3893)

You know what's coming next :lol:

(http://www.oem-cycle.com/forum/download/file.php?id=3894)

This needs some attention as well..

(http://www.oem-cycle.com/forum/download/file.php?id=3895)

All done..

(http://www.oem-cycle.com/forum/download/file.php?id=3896)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 23, 2016, 01:38:19 PM: So you take a ported to perfection and freshly plated cylinder with zero hours on it and what am I going to do?

(http://www.oem-cycle.com/forum/download/file.php?id=3908)

Oh yeah... you know what's coming next

(http://www.oem-cycle.com/forum/download/file.php?id=3909)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 24, 2016, 11:53:46 AM: (http://www.oem-cycle.com/forum/download/file.php?id=3927)

(http://www.oem-cycle.com/forum/download/file.php?id=3930)

(http://www.oem-cycle.com/forum/download/file.php?id=3934)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 25, 2016, 10:08:37 AM: Counter sprocket bolt tower is done..
Before

(http://www.oem-cycle.com/forum/download/file.php?id=3807)

After
(http://www.oem-cycle.com/forum/download/file.php?id=3946)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 28, 2016, 11:52:57 AM: All the transmission parts have been cleaned including the clips and all the new gears.
This one has many new gears including both 3rds and 4ths.

(http://www.oem-cycle.com/forum/download/file.php?id=3964)

(http://www.oem-cycle.com/forum/download/file.php?id=3963)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 29, 2016, 02:59:23 AM: Fresh out of the oven..

(http://www.oem-cycle.com/forum/download/file.php?id=3965)

Fresh from the freezer.

(http://www.oem-cycle.com/forum/download/file.php?id=3966)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 29, 2016, 03:00:27 AM: So your all ready for the big moment.... And what's gonna happen?
Watch the master at work :-o

https://www.youtube.com/watch?feature=player_embedded&v=0JEPlaw_ZU8 (https://www.youtube.com/watch?feature=player_embedded&v=0JEPlaw_ZU8)

Ok, so the crank is in and that's the easy part... Watch the master install the other case half..

https://youtu.be/Wp9g4RDLnow (https://youtu.be/Wp9g4RDLnow)

Easy peasy :-D
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 29, 2016, 03:00:55 AM: Now it's time to install and torque the case bolts.

(http://www.oem-cycle.com/forum/download/file.php?id=3967)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: LukeG on February 29, 2016, 05:42:53 AM: That easy bake oven makes life easy!
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on February 29, 2016, 07:03:00 AM: It sure helps 8-)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on March 12, 2016, 06:58:28 AM: Since we are waiting for the custom ported cylinder to get back from Milennium Tech Jason went ahead and rebuilt the clutch basket with a new basket 8-)

It turned out sweet...

(http://www.oem-cycle.com/forum/download/file.php?id=3973)

(http://www.oem-cycle.com/forum/download/file.php?id=3972)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on March 18, 2016, 11:56:33 AM: A tip from Alward25, dimple the bolts to help prevent them from backing out..
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on March 18, 2016, 11:59:41 AM: Ok... so Kevin purchased a VF2 reed from me so I told him I would do all the boot mods for free.

Here we go..

Stock boot..

(http://www.oem-cycle.com/forum/download/file.php?id=4002)

Ears are removed and sanded flat..

(http://www.oem-cycle.com/forum/download/file.php?id=4003)

Now whip out the VForce 3 reed and stuffer..... What??? :? :? :?

(http://www.oem-cycle.com/forum/download/file.php?id=4004)

Yes... Put the VF3 in there with the stuffer..

(http://www.oem-cycle.com/forum/download/file.php?id=4005)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on March 18, 2016, 12:01:01 PM: Now put some silicone of some type on the stuffer only...

(http://www.oem-cycle.com/forum/download/file.php?id=4007)

Now install the boot...

(http://www.oem-cycle.com/forum/download/file.php?id=4008)

Let it dry over night

(http://www.oem-cycle.com/forum/download/file.php?id=4009)

Reach in there and feel around with your finger... You will understand why I do this mod..
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: Pmcg on March 18, 2016, 11:12:47 PM: Your motors look so good. I need a vapor blaster
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on March 19, 2016, 02:37:20 AM: We all need a vapor blaster :lol:
If I was starting all over again it would be one of the first things I would buy.
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: Foxx4Beaver on March 19, 2016, 02:48:28 AM: Quote from: sandblaster on March 19, 2016, 02:37:20 AM
We all need a vapor blaster :lol:

absolutely!....my KX's, the KZ, my sled, and my trucks would all look totally different if I had one!...so amazing the transformation from "before & after".
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: Motorrad on March 19, 2016, 03:03:05 AM: (http://www.oem-cycle.com/forum/download/file.php?id=4009)

Reach in there and feel around with your finger... You will understand why I do this mod..

I hope you bought it dinner first
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on March 19, 2016, 11:51:46 AM: After the goop has set up, carefully remove the boot and take a look at what you have..
Note the difference in the boot hole VS the stuffer hole..

(http://www.oem-cycle.com/forum/download/file.php?id=4010)

Clean away the excess goo without breaking the stuffer from the boot.. Then get a marker and mark the boot.

(http://www.oem-cycle.com/forum/download/file.php?id=4011)

Now remove the stuffer from the boot and see what you have..

(http://www.oem-cycle.com/forum/download/file.php?id=4012)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on March 19, 2016, 11:52:40 AM: That yellow profile need to go away..
The first time I ever did one of these I used a small sanding drum on a Dremel.
My tools have improved somewhat since then...

(http://www.oem-cycle.com/forum/download/file.php?id=4013)

It's still a little rough but you get the idea..

(http://www.oem-cycle.com/forum/download/file.php?id=4014)

Now you can compare the VF3 stuffer and make sure that you didn't miss anything...
NEXT!!!! :-D
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: Foxx4Beaver on May 03, 2016, 07:54:24 AM: (http://upload.wikimedia.org/wikipedia/commons/1/17/Belize_Speed_Bump_Sign.JPG)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on May 03, 2016, 09:38:38 AM: (http://www.oem-cycle.com/forum/download/file.php?id=4034)

(http://www.oem-cycle.com/forum/download/file.php?id=4043)

Shipped! 8-)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on May 03, 2016, 09:39:34 AM: The customer is breaking it in right now but reports that it has a lot more power then before... :lol:
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: Foxx4Beaver on May 03, 2016, 09:50:40 AM: there's the "BUMP" I was waitin for. :mrgreen:
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on May 03, 2016, 10:13:45 AM: I want to see him race it up at Washougal..
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: Foxx4Beaver on May 03, 2016, 10:17:01 AM: Quote from: sandblaster on May 03, 2016, 10:13:45 AM
I want to see him race it up at Washougal..

there ya go!...that would be cool to see 8-)...that place looks like a beautiful facility, with nice dirt.
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on August 03, 2016, 02:06:56 AM: Here is some updated pics..

(http://www.oem-cycle.com/forum/download/file.php?id=4361)

(http://www.oem-cycle.com/forum/download/file.php?id=4362)
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: Foxx4Beaver on August 03, 2016, 07:16:24 AM: that thing's gorgeous!!
I'm not a fan of the "KX logo-less" seat cover...but thing looks awesome!
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: DoldGuy on August 03, 2016, 03:31:38 PM: Now Kevin needs to update us on the suspension...especially that front end. :-D
Title: Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
Post by: sandblaster on August 03, 2016, 06:12:49 PM: Yeah... I've had several requests for more info... I'll pass along what he tells me.
On a similar note... Kevin's suspension will seem somewhat weak compared to something that Oscar is working on for Chris Colliers bike.... Sssshhhhhhh... It's a secret... :wink: