KX Riders
Maintenance & Technical => KX500 Original => Topic started by: MMVTwin on July 29, 2017, 10:36:25 PM
-
So as per the intro I picked up a 1920 KX500 that is a bit of a mess and basically wont start, spent two day kicking with a bit of a short fire and shut down, stripped the carb and cleaned up the tried tow starting where basically got it started but would run like a pig and just die ( unrideable) did a compression test and di about 110psi
here it is. Frame has a sump guard and water pump and rotor protectors welded to it and breather hose holder welded to the neck off the frame with a long range tank
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20729138_1898027310457151_2328500982405991786_o.jpg?oh=d020ab41b2812d243da7db59002e2124&oe=5A2BE60F)
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20748182_1898027397123809_3148231692676763291_o.jpg?oh=e7c42a21688420751bccfb2afea320c2&oe=5A33E360)
Pulled the rotor cover of this arvo to find rotor Crank nut siting in the cover and the rotor spinning on the tapered shaft of the crank, amazed it even fired up
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20819336_1898027317123817_3919226211569895764_o.jpg?oh=de167ed3b262a3a7660fb0c43564e609&oe=5A2D16A1)
so first up I wanna just try and get this thing running before I strip it down for a total rebuild
-
As you all have probably noticed, Photo-suck-it has declared war on all 3rd party hosting. Their decision was overnight and their only solution is a $399 per year plan for everyone. I will be working on a new site as soon as I get back from vacation. For now, you can right click on the photos and select open link in new tab. This will allow you to view the picture for now. I will be mid August until I have a new solution, so for now right click and open link away. :-D
-
Gents anyone able to give me the size of the woodruff key for the crank and rotor
cheers up front
-
Any updates on how to post Pics?
anyway got it running had a test ride and the bike is all torn down
Frame will get a few small repairs and engine is now soaking in degreaser and will get a wash tomorrow before getting stripped
Sandblaster is there anything I should be looking for when I start to strip this thing down?
-
I saw that you signed up at KX Guru..
I have revised your account to allow for immediate uploads of your pics.
Go there, upload your pics then, Right Click on a pic.
Select "Copy Image Location" if you are using Firefox...
Then, come here and insert the pic.
On things to look for... these are always good to know...
https://www.youtube.com/watch?v=eTjceU2M7kw (https://www.youtube.com/watch?v=eTjceU2M7kw)
-
got the motor all degreased and washed
made my own degree wheel and the ex timing come in at 202*s, with a .045" Head gasket, deck height of Piston was +.003" and recess in head was .002"
Barrel looks ordinary so will see if anyone down under can replate the cylinder
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20690198_459717197736085_6762511153349239149_o.jpg?oh=71c240c01b5b1bac4336df1c03e503d0&oe=59F89735)
-
can these cracks be repaired ?????
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20626314_459717207736084_6233711890872834207_o.jpg?oh=65f859d66c4ce6e25911d541038bed52&oe=5A30FA43)
-
We can't see any of your pictures.
Post them at your facebook account and then you can link them here.
This is all we can see
(https://scontent.fslc2-1.fna.fbcdn.net/v/t1.0-9/20638027_1529284837117957_1556217907533248929_n.jpg?oh=6f6d007db77c2ff8b9d51a5b92bc5e2b&oe=59F52929)
-
still nothing, I can see them now
-
We can't see them because it's not our photosucket account :-(
Likely you need to be logged in to see them.
I tried a few tricks to make it so I can view them and it's a no go...
The only pics I can get are on your facebook page..
-
If you join KX Guru Racing on Facebook and post the pics I can link them for you.
https://www.facebook.com/groups/179257569231617/ (https://www.facebook.com/groups/179257569231617/)
-
Just sent a request to join the facebook page.
photo bucket is poo
-
Approved :-o
-
Got it all stripped down the other
already has resign in the potential air sucking parts
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20643117_459904327717372_4800195375891819711_o.jpg?oh=8d06c32cabde8b6f36a9569c452a2598&oe=5A2BC28C)
clutch Basket has a busted finger
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20627070_459904014384070_6300418457140865725_o.jpg?oh=431b4f2d5cc20b8a7810662737f63578&oe=59F28902)
-
I fixed your pics.
Go to the your post and click on Modify.
You can see what I did so that you can make them appear instead of a link.
-
3rd gear out put sprocket needs replacing
(https://scontent-syd2-1.xx.fbcdn.net/v/t1.0-9/20708287_1898028093790406_7689183660256414682_n.jpg?oh=1254f6bede21ac1c6b1c856a72e3faf6&oe=5A200FD5)
Sandblaster I cant work out what ya did to make pictures show
From Sandblaster... You need to have the brackets on either side of your link with the characters as shown below.
on this post, click on "modify" and look at your link
[ img] Your link here with no spaces [/img ]
-
Take a look at your last post..
And, while you have the gear box apart, replace ALL the snap rings... 8-)
-
Take a look at your last post..
And, while you have the gear box apart, replace ALL the snap rings... 8-)
yes read that on another of your threads so that and bevelling the dogs will happen
any one out there got a 3rd input gear laying around????
-
This guy is crazy expensive (61.99 delivered in the USA) but he has one in good shape..
http://www.ebay.com/itm/KX500-KAWASAKI-2002-KX-500-02-TRANSMISSION-OUTPUT-THIRD-3RD-GEAR-26T-/371639500355?fits=Model%3AKX500%7CYear%3A2000&vxp=mtr&hash=item568770be43 (http://www.ebay.com/itm/KX500-KAWASAKI-2002-KX-500-02-TRANSMISSION-OUTPUT-THIRD-3RD-GEAR-26T-/371639500355?fits=Model%3AKX500%7CYear%3A2000&vxp=mtr&hash=item568770be43)
(http://i.ebayimg.com/images/g/iPYAAOSwepZXR2AQ/s-l1600.jpg)
(http://i.ebayimg.com/images/g/6JMAAOSwNsdXR2AI/s-l1600.jpg)
(http://i.ebayimg.com/images/g/vRkAAOSwR5dXR2AO/s-l1600.jpg)
-
Sandblaster I tried to send you a pm don't mean to jump in to your thread I'm new here but have been riding and working on 92 kx5 for 14 years. I just had a question about the kx5 center piston window mod from someone who has road with oneach first hand. Did the mod help you bike? Thx
-
I'm in the middle of a complete build as well any info is much appreciated
-
Sandblaster I tried to send you a pm don't mean to jump in to your thread I'm new here but have been riding and working on 92 kx5 for 14 years. I just had a question about the kx5 center piston window mod from someone who has road with oneach first hand. Did the mod help you bike? Thx
ask away mate
-
Crank measurements all within spec
Con Rod side clearance is .43mm (new ..40-.50)
Big end radial clearance is .03mm ( new .034 -.047)
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20819167_1898587487067800_4126115205367559583_o.jpg?oh=07301fa047682b0283a96cadc2be1635&oe=5A28A12B)
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20748396_1898587310401151_6388798372332510499_o.jpg?oh=85a92a29be4bb9af1742dccfcaa63adc&oe=5A2D7159)
-
cant seem to tell what purpose this serves and do I need to worry about a repair
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/20863363_1898586417067907_4028996493362015090_o.jpg?oh=fb5f66df5b926b06fe0f675050204417&oe=5A2B8834)
-
Hey Captain :lol:
That broken part is for the kick start return spring.
Have it welded.
But before you do anything get a piece of coat hanger or heavy wire that fits the hole.
Stick the wire in the hole.
That way when it is tig welded you don't deform the hole size or plug it up :-o
-
Sandblaster I tried to send you a pm don't mean to jump in to your thread I'm new here but have been riding and working on 92 kx5 for 14 years. I just had a question about the kx5 center piston window mod from someone who has road with oneach first hand. Did the mod help you bike? Thx
Hello.
Yep, I got the PM late last night but didn't respond because I was beat.
I have rode both pistons.
It is highly unlikely that you can feel a difference.
The biggest reason for the mod was cooling.
Stewart (The last speed record holder) developed this mod for the KX500 to decrease temps around the crown of the piston at sustained high speed WOT runs.
It does not make any HP but it will help keep the HP at it's peak longer.
There are other potential benefits such as better lubrication of the wrist pin ect.
So, should you window your piston?
Mmmm... for most it isn't required but it's not going to hurt a thing if you do but don't really need it.
On my next build I will be putting some holes in that area, but not a big hole :lol:
-
Hey Captain :lol:
That broken part is for the kick start return spring.
Have it welded.
But before you do anything get a piece of coat hanger or heavy wire that fits the hole.
Stick the wire in the hole.
That way when it is tig welded you don't deform the hole size or plug it up :-o
Rodger that
-
Thx blaster i really appreciate the response and info! Can't wait too ride the old girl again it's been too long. Looks like you got a lot going on with your own bike ill leave u too it.
-
Thx blaster i really appreciate the response and info! Can't wait too ride the old girl again it's been too long. Looks like you got a lot going on with your own bike ill leave u too it.
Bikes or no bikes.... I always have a lot going on Lol 8-)
-
Sad. I couldn't remember what that hole was for. Im losing it.
-
Sad. I couldn't remember what that hole was for. Im losing it.
:roll:
-
Sad. I couldn't remember what that hole was for. Im losing it.
:roll:
we all have them moments :oops:
-
Been busy fixing Harleys last couple of day so I haven't got nothing done on the KX
Cases are of betting Vapour blasted and kick start spring hole repaired, Frame and sub frame are off for some weld repair
over next few days will order circlips and seals also got get busted seize axle adjuster out of swing arm
-
Vapor blasting is the coolest ever.
Just be sure to take time to clean out every crack, threaded hole, and crevice.
(http://www.oem-cycle.com/forum/download/file.php?id=4833)
(http://www.oem-cycle.com/forum/download/file.php?id=4795)
-
Sad. I couldn't remember what that hole was for. Im losing it.
:roll:
we all have them moments :oops:
You don't know Motorrad.... Lol... His entire life is a moment :lol:
-
far out I hope my cases come out like that
-
far out I hope my cases come out like that
Correct media, air pressure, mix ratio, nozzle velocity, and attention to detail and they will :-o
-
so I have had the cases blasted and fitted new bearings and circlips to the gearbox shafts, frame had some weld repairs and been powder coated
(https://scontent-syd2-1.xx.fbcdn.net/v/t1.0-9/21078619_1904343243158891_1577566851121366050_n.jpg?oh=8ab0bdd87f0597d5407b13e4b8ace117&oe=5A196DD2)
http://(http://width=640 height=480]https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/21200649_1904343193158896_7231404477614952012_o.jpg?oh=9a51603dc12939ba1a2b02d04af1f202&oe=5A20F73B)
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/21083757_1904343146492234_1326234646471444778_o.jpg?oh=177765b830feb8e0286a1aca364d119d&oe=5A253485)
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/21199666_1904343126492236_4582924740656743262_o.jpg?oh=b68087962efd1cdaf16906b669af0056&oe=5A1FCEB6)
One problem I have and maybe a trick to it or Iam missing something is that I cannot pull the clutch cover home over the kick stater shaft and spring as in the below pic, looking for any ideas as I have even removed the clutch basket and it will not pull down over the kick start shaft
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/21167372_1904343209825561_6448554340328758738_o.jpg?oh=272145146674f93857fa2826a2c56a73&oe=5A245DC8)
-
few more pics
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/21167603_1904343006492248_6319062483629656655_o.jpg?oh=a0766e5b9244fe05afc69caf5347de28&oe=5A20516F)
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/21125525_1904342999825582_4792658961248389495_o.jpg?oh=317db8812e49aa856da1eaa2e7e6a684&oe=5A5F44FF)
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/21167646_1904343003158915_3482819350227740289_o.jpg?oh=04fafb731e55a162944a17b1de239659&oe=5A244FD2)
(https://scontent-syd2-1.xx.fbcdn.net/v/t31.0-8/21200649_1904343193158896_7231404477614952012_o.jpg?oh=9a51603dc12939ba1a2b02d04af1f202&oe=5A20F73B)
-
Check kick start shaft return spring, if it's not 100% correctly fitted it will cause this. If in question, simply remove the spring & try to reinstall the cover.
DoldGuy
-
Check kick start shaft return spring, if it's not 100% correctly fitted it will cause this. If in question, simply remove the spring & try to reinstall the cover.
DoldGuy
The kick start urethane bush was not seated correctly over the shaft and the spring