KX Riders

Commercially available service offered by members of KXRiders. => OEM-CYCLE => Topic started by: sandblaster on March 12, 2016, 07:05:30 AM

Title: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 12, 2016, 07:05:30 AM
Ok... Disassembling another KX500...
When you see this.... It's not a good thing  :|

https://youtu.be/mzAoHiYxiqs (https://youtu.be/mzAoHiYxiqs)
Title: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Foxx4Beaver on March 12, 2016, 08:37:03 AM
did I see the bearing come with it?...then hear it drop back into journal?...looked effortless.
Title: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 12, 2016, 12:04:47 PM
No, the bearing stayed in the case.. So that's all good :-)
Title: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 08:05:41 AM
On this build we were hoping to save the crank and the top end and simply replace all the bearings, seals, washers, snap rings, bushings, ect.
This is what we received..

(http://www.oem-cycle.com/forum/download/file.php?id=3974)

Looks good...

The head came off and.... Looks good as well...

(http://www.oem-cycle.com/forum/download/file.php?id=3975)

Recorded the head squish

Piston and cylinder bore look decent..

(http://www.oem-cycle.com/forum/download/file.php?id=3976)
Title: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 08:07:21 AM
With a weight like that, this is definitely a trail rider

(http://www.oem-cycle.com/forum/download/file.php?id=3977)

Gonna need some new reed pedals..

(http://www.oem-cycle.com/forum/download/file.php?id=3978)

Measure and record the piston at TDC to the cylinder deck..

(http://www.oem-cycle.com/forum/download/file.php?id=3979)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 08:08:15 AM
Gonna need some welding and fab work  :-o

(http://www.oem-cycle.com/forum/download/file.php?id=3980)

Measure and record the ports.... All stock.... Ignore the reading on the wheel

(http://www.oem-cycle.com/forum/download/file.php?id=3981)

Here is where we found some issues..

(http://www.oem-cycle.com/forum/download/file.php?id=3982)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 08:09:13 AM
Unfortunately the piston wall is getting thin and it's got a dink in it.....

(http://www.oem-cycle.com/forum/download/file.php?id=3983)

Also the crank has some strange grinding marks on the side of it..

(http://www.oem-cycle.com/forum/download/file.php?id=3984)

It also has a lot of galling around the flywheel.... hmmmmm

(http://www.oem-cycle.com/forum/download/file.php?id=3985)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 08:10:08 AM
Then a closer inspection of the plating reveals some thin plating and some issues around the ports..

(http://www.oem-cycle.com/forum/download/file.php?id=3986)

Maintenance was not a issue on this bike.
Look how clean it is on the inside..

(http://www.oem-cycle.com/forum/download/file.php?id=3987)

The customer uses Royal Purple Synthetic 10/30

(http://www.oem-cycle.com/forum/download/file.php?id=3988)

I've been thinking about trying it for some time..
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 08:11:00 AM
Helicoil drain plug... We may have to fix this..

(http://www.oem-cycle.com/forum/download/file.php?id=3989)

Hmmm, I'm not certain what balance factor they were shooting for but these holes are a no go..

(http://www.oem-cycle.com/forum/download/file.php?id=3990)

It's a shame that this top end has very little time on it and for some reason it has some issues..

(http://www.oem-cycle.com/forum/download/file.php?id=3991)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 08:12:16 AM
Nice, clean, stock cylinder

(http://www.oem-cycle.com/forum/download/file.php?id=3992)

I'll fix that  :-o Got some roughing work to do..

(http://www.oem-cycle.com/forum/download/file.php?id=3993)

(http://www.oem-cycle.com/forum/download/file.php?id=3994)

(http://www.oem-cycle.com/forum/download/file.php?id=3995)

I finished the porting at about 12:30 this afternoon and got it shipped to Millennium Tech for plating... Oh yeah! :D
No, these pics are of the roughing work, not the finished cylinder  :wink:
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Foxx4Beaver on March 14, 2016, 08:38:37 AM
Quote from: sandblaster on March 14, 2016, 08:10:08 AM
The customer uses Royal Purple Synthetic 10/30

I've been thinking about trying it for some time..

wasn't Motorrad using that at one time?....or at least an RP product in the tranny.
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 10:25:36 AM
He has used Royal Purple Purple Ice in the Rad...
I don't think he ever ran it in the trans.
Although he was looking into it at one time.
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Foxx4Beaver on March 14, 2016, 10:31:16 AM
Quote from: sandblaster on March 14, 2016, 10:25:36 AM
He has used Royal Purple Purple Ice in the Rad...
I don't think he ever ran it in the trans.
Although he was looking into it at one time.

he did...bout 1/2 way down...
http://www.kxriders.com/forums/index.php/topic,8310.0.html

couple more...
http://www.kxriders.com/forums/index.php/topic,7711.0.html
http://www.kxriders.com/forums/index.php/topic,5041.15.html
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 11:38:53 AM
Wow!
That first post was a bit before my time here.
Those were the Stewart days  :-o
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 14, 2016, 11:39:55 AM
Found out today that the shift forks were out of spec so we are replacing them as well  :|
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Mohave on March 18, 2016, 02:55:30 PM
Mohave here having Sandblaster work his magic.
One comment on the reeds...I wonder if a corner coming off could cause a dent in the piston?
I mean you have fiberglass versus metal...so I think the metal would win?

Anyways the reeds chipping is kinda scary becuase those are OEM from Rocky Mountain or Service Honda.
And they may, maybe, have 40 hours or so of engine time.

So why did they chip?  Anyone know if the carbon fiber are longer lasting than the fiberglass?

Suggestions?
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Motorrad on March 18, 2016, 03:19:51 PM
Is Mohave one of the heads I have here to cut?
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 18, 2016, 04:44:28 PM
Yes it is.... but I wasn't going to call it  :-o
But now that the cat is out of the bag let the fun begin  :-D
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Motorrad on March 19, 2016, 03:01:24 AM
Quote from: sandblaster on March 18, 2016, 04:44:28 PM
Yes it is.... but I wasn't going to call it  :-o
But now that the cat is out of the bag let the fun begin  :-D
Which one?  #1 or #2?
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Mohave on March 19, 2016, 05:07:25 AM
So I wanted to see what everyone thought about reeds.  I have it down to two candidates.

This one:

http://www.ebay.com/itm/Moto-Tassinari-Reed-Cage-Valve-System-VForce-3-Kx500-Kx-500-1987-2004-V3R08-/231391405252?fits=Model%3AKX500&hash=item35e000a4c4:g:BgEAAOSwMmBV3Hta&vxp=mtr

or just new carbon reeds:

http://www.ebay.com/itm/KAWASAKI-KX500-BOYESEN-PRO-SERIES-REEDS-KX-500-86-04-/290730319662?fits=Model%3AKX500&hash=item43b0e09f2e:m:mv0lw-5UYLWmgviEA4u-EPg&vxp=mtr

The Moto-Tassinari has no screws that I can see to ever come out but I use loctite anyways on the stock cage.

Anyone know if the Moto Tassinari is that much better than stock?  For $50 you get new reeds, for $125 a whole new assembly.  Any thoughts?
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: mikectanker on March 19, 2016, 07:41:14 AM
There are some big write ups on the reeds here if you search. I have a new vforce 3 that I'd be glad to give you a deal on. I highly suggest
researching what sandblaster found on the vforce 3 vs vforce2 before buying anything.

Read this---> http://www.kxriders.com/forums/index.php/topic,11799.0.html
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Motorrad on March 19, 2016, 11:19:09 AM
Quote from: mikectanker on March 19, 2016, 07:41:14 AM
There are some big write ups on the reeds here if you search. I have a new vforce 3 that I'd be glad to give you a deal on. I highly suggest
researching what sandblaster found on the vforce 3 vs vforce2 before buying anything.

Read this---> http://www.kxriders.com/forums/index.php/topic,11799.0.html


Yep that sandblaster fellow Is a pretty sharp guy.
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 19, 2016, 11:39:00 AM
Quote from: Motorrad on March 19, 2016, 03:01:24 AM
Quote from: sandblaster on March 18, 2016, 04:44:28 PM
Yes it is.... but I wasn't going to call it  :-o
But now that the cat is out of the bag let the fun begin  :-D
Which one?  #1 or #2?

It is the last one I sent you.
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 19, 2016, 11:41:33 AM
Quote from: Motorrad on March 19, 2016, 11:19:09 AM
Quote from: mikectanker on March 19, 2016, 07:41:14 AM
There are some big write ups on the reeds here if you search. I have a new vforce 3 that I'd be glad to give you a deal on. I highly suggest
researching what sandblaster found on the vforce 3 vs vforce2 before buying anything.

Read this---> http://www.kxriders.com/forums/index.php/topic,11799.0.html


Yep that sandblaster fellow Is a pretty sharp guy.


Uhhhhh... Sure.... I groped around in the dark until Motorrad turned on the lights and all the little bugs went scurrying out of the light  :-P
I heard all the talk but didn't fully understand until I cut a cylinder in half and said, "OH!!!! That's what Motorrad was talking about!!!"
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Motorrad on March 19, 2016, 04:22:14 PM
Quote from: sandblaster on March 19, 2016, 11:39:00 AM
Quote from: Motorrad on March 19, 2016, 03:01:24 AM
Quote from: sandblaster on March 18, 2016, 04:44:28 PM
Yes it is.... but I wasn't going to call it  :-o
But now that the cat is out of the bag let the fun begin  :-D
Which one?  #1 or #2?

It is the last one I sent you.

Cool.. Mojave gets the secret squirrel "M" head cut....
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on March 19, 2016, 04:57:26 PM
And he will like it too :-)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Mohave on March 20, 2016, 07:05:11 AM
Cool...secret squirrel head cut...now that is something I would have never thought to associate with a KX500... :?
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Mohave on March 20, 2016, 07:15:33 AM
So I read the thread that mikectanker was kind enough to put out there...thanks.
Looks like the best bang for the buck would be the stock cage with the carbon fiber reeds and maybe a spacer.

I ran a spacer before and liked it, I think Sandblaster ended up with it.  A little harder to put the carb on but not bad.
And I dont remember it rubbing anything.  It did not change my jetting either.

VF2 are hard to find and will be more money.  But they look like the hot ticket.
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on April 19, 2016, 03:45:12 AM
Verifying all the parts were in..

(http://www.oem-cycle.com/forum/download/file.php?id=4019)

Installing the main bearings and seals:

(http://www.oem-cycle.com/forum/download/file.php?id=4024)

Droppin in the crank:

(http://www.oem-cycle.com/forum/download/file.php?id=4025)

Lubin up the trans parts:

(http://www.oem-cycle.com/forum/download/file.php?id=4022)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on April 19, 2016, 03:47:25 AM
Trans installation:

(http://www.oem-cycle.com/forum/download/file.php?id=4027)

Picasso at work...

(http://www.oem-cycle.com/forum/download/file.php?id=4029)

Motorrad's head cut..

(http://www.oem-cycle.com/forum/download/file.php?id=4030)

When the cases snap shut without a fuss, you know you did something right

(http://www.oem-cycle.com/forum/download/file.php?id=4033)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on April 19, 2016, 03:48:43 AM
Good stuff here:

(http://www.oem-cycle.com/forum/download/file.php?id=4034)

YES!!!

(http://www.oem-cycle.com/forum/download/file.php?id=4036)

OH YEAH!!!

(http://www.oem-cycle.com/forum/download/file.php?id=4037)

Checkin it twice:

(http://www.oem-cycle.com/forum/download/file.php?id=4035)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on April 19, 2016, 03:49:34 AM
Evil twins  :-o

(http://www.oem-cycle.com/forum/download/file.php?id=4039)

Ship it!
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Foxx4Beaver on May 03, 2016, 07:19:30 AM
any ride reports from Mohave yet??
or even some video footage.
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on May 03, 2016, 09:41:12 AM
He is close to having it all back together..
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: sandblaster on May 03, 2016, 09:48:39 AM
(http://www.oem-cycle.com/forum/download/file.php?id=4086)

(http://www.oem-cycle.com/forum/download/file.php?id=4087)

(http://www.oem-cycle.com/forum/download/file.php?id=4088)

(http://www.oem-cycle.com/forum/download/file.php?id=4085)
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Foxx4Beaver on May 03, 2016, 09:52:29 AM
nice!
man that looks sweet!!

is that an 18" rear?
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: Mohave on May 03, 2016, 03:44:14 PM
Yep 18 inch rear wheel.  Run a Maxxis desert with tubliss at 5psi.
Works great in the desert, never had a flat.  Great everywhere but long stretches of mud.

Which in the desert is not often.  Hope to start break in tomorrow.
Title: Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
Post by: USMC 500 on May 06, 2016, 01:53:32 PM
MOHAVE......good to hear from you.  Been a long time since our last ride.  Glad to see that Blaster and the Moustache got their paws on your engine.  You won't be disappointed.  I ended up moving back to Los Angeles.  How you been?