KX Riders
Maintenance & Technical => KX100 / KX85 / KX80 / KX65 / KX60 => Topic started by: Coop on June 13, 2010, 05:17:10 AM
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I bought a 1994 KX60 for my nephew recently. I got it really cheap and it came with a new cylinder. The guy said it just needed a piston/rings/gasket kit, but I suspected bottom end issues because these 60's are known to for that. Upon tearing into the engine I found a bad crank; the lower rod bearing race broke and that is what fragged the top end. I hope to start ordering parts this week. The frame and swing arm are getting repainted OEM colors. This is not a restore, just a refurbish so my nephew has a good looking, clean running bike to ride.
I am looking for opinions on engine finish. Should I paint it, or sand/bead blast it?
At the guys house:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-1.jpg)
About an hour after we got home:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-2.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-4.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-3.jpg)
I spent about an hour the other day and finished tearing the engine down:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/cases.jpg)
Bad parts so far, well everything but the oil glass I broke, lol. I was pushing it out so the cases were bare for finish and I managed to hamfist it and crack the glass haha.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/badparts.jpg)
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Yesterday I ordered the Wiseco complete crank kit with bottom end gaskets and seals, complete piston kit with top-end gaskets, a new shift lever to replace the mangled one, the parts to rebuild the water pump, and found a bolt kit on eBay. More than half the bolts on this bike were stripped and I do not plan on putting them back in like that.
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Some of the parts came today:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/Parts.jpg)
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So this project might go into hurry up mode and the cosmetic stuff might wait until winter. Once my nephew heard I started getting parts in, he said "Just put it together Uncle Mike, I want to ride!" :-D
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I would do the cosmetic stuff. You will not have another opp to paint the frame. As far as the engine goes glass bead blast it. if you use sand it will be dull and gray. Glass bead will give it that bright silver factory look but you have to be double sure that you get it all out of the engine parts before you put it together. Make sure you blow out all of the bolt hole very well and put on some safety glasses. A little bike like this will bring more little kids happiness then just your Nephew. If you do a good job on it now then when your nephew out grows it and your buddies kid is learning on it the bike will still look good. Not to mention resale value will be higher but a kx60 is one of those bikes you never get rid of in my opinion. O ya and get the kid in on the project even if all he does is watch his uncle mike, chances are he will have as much fun as ridding it.
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Well since the bolt kit is going to take longer than expected I decided to do some painting. I got the swingarm cleaned, sanded, and painted today. Yes it's just rattle can, yes I know it will scratch and chip easily, no I don't care, ;D . It's going to a 10 year old who is going to beat it I'm sure. I just want it to look nice when he first "officially" gets it.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/Swingarm.jpg)
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I decided since funds are limited I would just apply a healthy dose of elbow grease and clean the cases instead of getting them bead blasted. A wire brush, some Simple Green and then Purple Power when I ran out of SG. They are not perfect, but they look much nicer.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/CleanCases.jpg)
I also painted the ignition and clutch side covers. The clutch side came out like crap, must have missed some oil. So I stripped it down and will re-spray it later or tomorrow.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/IgnitionCover.jpg)
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looking good. I love watching these rebuild projects.
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Starting to look like an engine:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/clutchcover.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/tranny1jpg.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/bottomend.jpg)
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I have a pro circuit pipe and silencer for tha bike. I'll send it if you need it. Get that boy riding!
Let us know how that Ebay bolt kit turns out. Quality or not!
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Looking Good Coop!
Not only do you get to put together another bike, You get to get a kid out in the dirt!
Thank you ThrottleJunkey for making the offer to Coop. That's what makes this place the best little site on the web.
Tuck\o/
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How much would you want for that pipe ThrottleJunkey? This one is almost crushed right before the silencer, I am worried how that will affect performance.
The bolt kit is very nice! Definitely worth the $20. It was much nicer assembling the cases instead of the stripped phillips screws. The kit came with the case bolts, ignition cover bolts, clutch cover bolts, water pump bolts, and reed bolts.
Here's a crappy cell phone picture of the finished engine. The cylinder and head are way brighter than the cases, but it's ready to run. I called Nick today and told him his engine was done and he said "YES!". I have the frame sanded and will paint it tomorrow (just rattle can, money is tight) and then I get to start putting it all back together.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/moto_0139.jpg)
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Coop, The pipe and silencer aren't for sale. PM me your shipping address.
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Wow thank you! Really. Nick is so excited about riding this bike. It's great. He gos to church camp next week but tried to cancel because he knows his bike will be done :-D .
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Frame is painted. It's lighter than I wanted (almost looks like shiny primer) but I couldn't find the shade I wanted in a rattle can. Once the new steering stem bearings come in I will start putting it back together.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame2.jpg)
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I spent an hour in the garage. I got the engine in, swingarm on, brake assembly installed, electronics hooked up, and checked spark.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame4.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame6.jpg)
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Coop,
You are going to make your Nephew VERY HAPPY! :-D
DoldGuy
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Hey Coop, what size pants, jersey, and boots does your nephew wear? Finally came across the ideal box to ship the pipe. Could throw in some gear too.
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Thanks again for that pipe! The gear would be put to use for sure, but you really don't have to do that! I'm not exactly sure on sizes for gear. He's short for 10, but weighs around 100#? My sister-in-law told me recently he wears a size 6 in shoes, but didn't say if she meant adult or youth 6. I am not real good with kid sizes, lol. I have this picture from his last ride on the 50 before we sold it. This riding gear we borrowed from a friend and it's baggy on him. Size 28 pants and I am guessing adult small jersey? I just looked and can't find a size in the jersey. No boots yet which is top priority before he starts riding the 60 since it will be fast.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/PW50/pw-1.jpg)
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I haven't made much progress the last two days. I did sneak out today and get the carb and airbox on. It needs steering stem bearings and of course the races are badly grooved, so instead of just replacing the ball bearings I had to order new tapered bearings. I had to scrape up the cash so it took me a few days to get them ordered. They should be in tomorrow (hopefully). This has been a fun project and I will only have slightly more in it than running KX60's sell for around here, but Nick's bike is going to be basically new compared to some clapped out unknown used bike.
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Coop,
Make sure you post some pics of the Great Big Smile on that lucky kid once he sees it for the first time (Think we all had a day like that). It's great for him to have an Uncle as yourself to invest all of the time (& dollars) to share a passion. Kept me out of trouble as a youth.
Throttle Junky,
Your generosity is what makes this the place to hang out, members like you are not easy to find!
DoldGuy
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Oh yeah I'll take plenty of pics, and hope to get some video maybe of his first ride on it.
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Nice thread...kinda crazy all the parallels between this build and the one I'm doing for my son. I bought a '99 KX60 with a rotten crank and trashed top-end back in September '09.
Working two jobs I haven't had much time to devote to the KX60 project. Over several months I've managed to recover the seat, yank the engine, clean up the roller pretty well, and install a new rear knobby. I have big plans for the original engine, but in the meantime I decided to bite the bullet and get my son an engine off of eBay (seller has over 200 feedback, all positive, and he says that the engine was rebuilt from the crank out). I really wanted to have the bike ready to ride when my son got back from church camp, unfortunately the engine has yet to arrive. Worse yet, the seller hasn't answered any of my messages in over a week. So the bike may have to wait for the 70.65cc big bore I'm building out of the original engine.
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Man I hope that seller comes through with your engine!
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No doubt. I paid using PayPal though, and I believe there's some sort of consumer protection available through them...
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Yeah there is. I bought some bmx handlebars for a different nephew and the seller never shipped them. Paypal got my money back.
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Poor quality cell phone pic.
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Looks good. I like that blue seat much better than the purple one on Nick's. I plan to replace it with a black cover if I ever get a few extra bucks for non-necessary stuff.
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The blue cover is definitely better than the green one it came with stock. Kawasaki didn't know when to say when on the green...
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I got the stem bearings in, the triples on, disassembled the shock, cleaned it, painted the spring, lubed all the bearings, used the wire wheel on the link, painted the top mount, and got it all put back together. I didn't realize until today, that this bike has an after market shock. It had a Works Performance sticker but I didn't think anything of it until in the manual I realized the stock shock didn't have the reservoir.
The wheels need a lot of love so it may be a couple days before I get back to assembly. Once I get those cleaned up though, it won't be but a couple hours until it's done. I do not care for the purple CEET seat cover or purple/pink/yellow CEET radiator shroud graphics but I am leaving it up to Nick to see and decide if he he wants me to change it.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame7.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame8.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame9.jpg)
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Nice! You gotta be stoked about that rear shock.
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Yeah that's a nice bonus for sure.
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I got the forks and bars on tonight. I had a few minutes to spare in the garage. I don't like those bars (they were on it when I bought it) but the funds have run dry for this bike so it will have to wait. I also want to replace those rusty bolts on the rear link, I tried cleaning them on the wire wheel but they didn't clean up very well.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame10.jpg)
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Painted the radiator with aluminum high heat paint, think it looks pretty trick. Mounted the hand controls, throttle and throttle cable, grips (Nick picked green, I wanted black), mounted the radiator, installed the hoses and shroud. I also mounted the rear mud guard and top shock cover. Once I get the pipe I will finish the assembly. ThrottleJunky is donating a Pro Circuit pipe and silencer to the project so I am waiting for it before I continue. I think the tank and wheels are going to take away from the project some cosmetically. The spokes are really rough and the tank is really dark on the top with faded spots where old graphics used to be. I tried a heat gun, wet sanding, and rubbing compound and none of them did anything at all. I am out of money though so the spokes and tank will have to wait, along with the ugly handlebars, lol.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/rtside.jpg)
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I guess I've always lucked out on old, faded fuel tanks. If they're bad enough, you can scrape the old, discolored layer off with the edge of a coin...almost like a scratch-off lottery ticket. But if you've already wet-sanded without good results, scratching it off probably wouldn't work.
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Hey Coop Lookin' great!
I have had good luck with scotch brite pads or S.O.S pads on the spokes and rims of older bikes. and if they're really bad sandpaper and THEN Scotch-Brite yeah, its' boring & tedious... and then you have to get out some polishing compound... more tedium and sore fingers, and if you don't wear gloves, black oxidation sore fingers... hey, wait a minute... that would be an excellent job for the nephew! after all it is His bike right! :-D
Hang in there Bro!
Tuck\o/
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i have seen people dye tanks with great results. it was on the orange ktm tanks and they dye them black turns out really good if you want the tank black.
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Here is the tank:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/tank.jpg)
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ThrottleJunky, your generosity is amazing! Not only did I get this very nice pipe and silencer in the mail today, but also a second box with boots and chest protector in it!
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/PCpipe.jpg)
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if you would like to dye the tank black i could get you some instructions. IMO it would look better all black than 2 shads of green.
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if you would like to dye the tank black i could get you some instructions. IMO it would look better all black than 2 shads of green.
I think I have to agree with you. I would appreciate the instructions for sure.
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if you would like to dye the tank black i could get you some instructions. IMO it would look better all black than 2 shads of green.
x2 on the tank dye instructions. I'm stoked to make it black.
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here is the link to the thumper talk thread. its a pretty good right up. the only thing is he dyes the in side of the tank. i strongly recommend not to. get some plugs or something to keep the dye out of the inside. in the right up he states it wont hurt cumbustion if the dye comes off but it can f the carb. just fill the tank with boiling water and submerge it. the in side will still be green but the out side will be pretty black. also some people have had to do it 2 times to get the proper color. orange KTM tanks come out brownish the after the first dip and then look perfect after the second dip.
http://www.thumpertalk.com/forum/showthread.php?t=611365&highlight=tank+dye (http://www.thumpertalk.com/forum/showthread.php?t=611365&highlight=tank+dye)
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the way i have died parts before is with my wifes stew pot (when shes not home), use RIT close dye, bring dye and water to a boil put parts in and cook them for a little while. the longer you leave in the darker they get. this works with all the little brake hose holders to. i also buy moose clear fuel and vent lines and dye them, it looks trick :-D
just remember its easier to start with white or clear parts, i know some times you got to go with what you have, good luck
p.s. i have a uncle like you that got me in to dirt bike$
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Thanks for the link bigbellybob . I don't have an extra $30 for that dye project right now, but may try that when I do. Like I said the tank and wheels are going to make it look not as nice as it should. I have sanded on the spokes for a full day and they still look really bad. Too many years of neglect I think by the previous owner. When/if I get the money I think I will just rebuild the rear wheel with new spokes. I want it to look nice, but can't stop the project because I can't afford new spokes or a tank dye job, haha.
I hope to get time later tonight to pretty much get it all together, if not it will be tomorrow. I didn't realize it until this morning that the clutch perch is broken and the brake perch is stripped where the adjuster screws in so those will have to be replaced now, ugh, lol.
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Hey Coop,
I'm pretty sure I have a clutch perch, I'll check my stock tommorrow . (wed 14) It looks like that bike has a front disk, is that right?
I guess what I'm asking is do you need a brake lever or the whole brake master and lever?
Tuck\o/
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Front and rear are both drums. But Friar you don't have to do that, I am worried this thread is starting to look like I am just trying mooch parts, LOL.
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Starting to look like a bike. Luckily I was able to spin the shock reservoir down to miss the pipe but still also be clear of the shock. I need to figure out something for the silencer mount. If I use the mounting points on the frame and silencer, the silencer just goes into the pipe. If I fully fit the silencer into the pipe, it is about 1.5" too short to reach the frame mount. Maybe a short tab with two holes drilled, think that will be stiff enough? That or maybe bolt it to the frame, but use a short section of heater hose and two clamps to seal the lose pipe/silencer joint. I also need to get a pipe spring, the one from the stock pipe is too long, it hooks on with no tension, LOL. I think I'd like to find a sticker that says "60" to put where my brother stuck that green/black "KX" sticker. The wheels will be on tonight or tomorrow, then it's just get a couple of perches and it's done. The front tire has some cracks in it, but has been holding air since yesterday. So I am using it for now. I am excited to hear it run. I could start it now, but I want to wait until it's rolling.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/rtside2.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/lftside1.jpg)
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I like your short tab, bolted together better than the hose...
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I like your short tab, bolted together better than the hose...
I think I do too. I'll make them later or tomorrow. Thanks again man, that pipe is going to work great and look really nice.
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Had to bead blast and paint the pipe before sending it. It looked too rough. Maybe you can polish the pro circuit tag on the pipe. It'll be trick looking then...
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Had to bead blast and paint the pipe before sending it. It looked too rough. Maybe you can polish the pro circuit tag on the pipe. It'll be trick looking then...
Hey I like that idea!
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I would say it's 97% finished. I need to remove a link or two from the chain and install it, adjust the brakes, slap on a clutch perch & lever, tighten the kill switch, polish the PC plate on the pipe like ThrottleJunky suggested, add fluids and that's about it. All small stuff. Once it's "officially" done, I'll use the camera and take some nicer pictures.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/lftside2.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/rtside3.jpg)
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It's done! Started second kick, my nephew Zach is a witness, LOL. Followed the break in warm up and rode it easily around the yard a couple laps. It is very loud! I am going to repack the silencer tomorrow. Clutch cover gasket is also leaking a little and the shifting is sticky, you have to push the shifter down a 1/2" or so and then it will shift up into the next gear. I will have the clutch cover off tomorrow anyway so I will be able to check out the shifter mechanism. Zach insisted on the numbers, I don't like them. But it's not my bike so as long as Nick does it's all good. I have a bunch of stickers here, I am letting Nick decide which ones he wants on it and where. I will be sure to post pictures once he first see's it. Hopefully that's tomorrow.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-6.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-16.jpg)
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# 7, like bubba.
I bet he`s gunna be FAST!
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Haha, his older brother picked the number.
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I was finally able get to Nick up here tonight and I gave him the bike. It will stay here in my garage, because honestly I don't trust my brother not to sell it when he gets broke. Nick loved the bike. At first he couldn't start it, but he got the hang of it. I let him go through my sticker "collection" and he put quite a few on the bike, LOL. No riding tonight, but hopefully soon.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/Nick2.jpg)
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Bump.........again for Mets