Author Topic: KX500 Crank / cases issue  (Read 1662 times)

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Offline Dad of Alf

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KX500 Crank / cases issue
« on: November 18, 2019, 09:50:01 AM »
Hello all,
We recently purchased a second KX500 a spare bike for my young son to race. I know my way around engines and am familiar with the KX500 motor.
The engine is typical of an old worn out mx bike engine, and I'm in a bit of a dilemma on the best way forward. We have a bit of a budget to fix the engine, but not a huge budget. We're in the UK.

The casings are worn, to the point of a HARD HAND push into the case. They do not just drop in/out. Do I :
1. Centre dot the crank case face.
2. Loctite/bearing fit (glue).
3. Rebore the bearing hole and fit a larger O/D bearing.
If the best option is No3 what bearing do I use. I've read somewhere about a CRF main.
There are other issues with the crank, but one step at a time.
Many thanks
Kings

Offline sandblaster

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Re: KX500 Crank / cases issue
« Reply #1 on: November 18, 2019, 03:44:11 PM »
I moved your topic here as it is easier to find  8-)


If it's worn as in the pic I would choose 3 as the best option.
Honda P/N 91001-HP1-601
30X76X19  It is 4mm larger than a KX500 but all the other sizes are the same.

Fits the following:
Honda ATV 2006 TRX450ER A CRANKCASE ('06-)
Honda ATV 2006 TRX450R A CRANKCASE ('06-)
Honda ATV 2007 TRX450R A CRANKCASE ('06-)
Honda ATV 2007 TRX450ER A CRANKCASE ('06-)
Honda ATV 2007 TRX450ER 3A CRANKCASE ('06-)
Honda ATV 2007 TRX450R 3A CRANKCASE ('06-)
Honda ATV 2008 TRX450ER 3A CRANKCASE ('06-)
Honda ATV 2008 TRX450ER A CRANKCASE ('06-)
Honda ATV 2008 TRX450R A CRANKCASE ('06-)
Honda ATV 2008 TRX450R 3A CRANKCASE ('06-)
Honda ATV 2009 TRX450R A Crankcase
Honda ATV 2009 TRX450R 3A Crankcase
Honda ATV 2009 TRX450ER A Crankcase
Honda ATV 2009 TRX450ER 3A Crankcase
Honda ATV 2012 TRX450ER 3A - TRX450ER Crankcase
Honda ATV 2013 TRX450ER AC Crankcase
Honda ATV 2013 TRX450ER 3AC Crankcase
Honda ATV 2014 TRX450ER AC Crankcase
Honda ATV 2014 TRX450ER 3AC Crankcase

This Honda 91001-MEY-671 BEARING, RADIAL BALL (30X76X19) fits the following models and components:
Honda Motorcycle 2005 CRF450X AC - CRF450X Crankcase
Honda Motorcycle 2005 CRF450X A - CRF450X Crankcase
Honda Motorcycle 2006 CRF450X A - CRF450X Crankcase
Honda Motorcycle 2006 CRF450X AC - CRF450X Crankcase
Honda Motorcycle 2007 CRF450X A - CRF450X Crankcase
Honda Motorcycle 2008 CRF450X A - CRF450X Crankcase
Honda Motorcycle 2009 CRF450X A - CRF450X Crankcase
Honda Motorcycle 2012 CRF450X AC - CRF450X Crankcase
Honda Motorcycle 2013 CRF450X AC - CRF450X Crankcase
Honda Motorcycle 2014 CRF450X AC - CRF450X Crankcase
Honda Motorcycle 2015 CRF450X AC - CRF450X Crankcase
Honda Motorcycle 2016 CRF450X AC - CRF450X Crankcase
Honda Motorcycle 2017 CRF450X AC - CRF450X Crankcase

Some claim that the Suzuki LT500 bearings will also work.
IF that is true (I have not verified the bearing size yet) then these should fit.

Suzuki P/N 09262-30076

Suzuki ATV 1987 QUADRACER - LT500R Crankshaft
Suzuki ATV 1987 QUADRACER - LT500RL Crankshaft
Suzuki ATV 1988 QUADRACER - LT500RL Crankshaft
Suzuki ATV 1989 QUADRACER - LT500RL Crankshaft
Suzuki ATV 1990 QUADRACER - LT500RL Crankshaft
Suzuki Motorcycle 1978 SP370 Crankshaft
Suzuki Motorcycle 1980 GN400T Crankshaft
Suzuki Motorcycle 1980 GN400TX Crankshaft
Suzuki Motorcycle 1980 GN400XT Crankshaft
Suzuki Motorcycle 1979 SP370 Crankshaft
Suzuki Motorcycle 1980 GN400XX Crankshaft
Suzuki Motorcycle 1980 SP400 Crankshaft
Suzuki Motorcycle 1981 GN400T Crankshaft
Suzuki Motorcycle 1981 GN400XX Crankshaft
Suzuki Motorcycle 1981 GN400TX Crankshaft
Suzuki Motorcycle 1981 GN400XT Crankshaft
Suzuki Motorcycle 1982 GN400T Crankshaft

You might get away with option 2 but I would use a retaining compound such as LOCTITE 660.
LOCTITE 660 is designed for the bonding of cylindrical fitting parts, particularly where bond gaps occurs such with worn parts, without the need for remachining.
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Dad of Alf

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Re: KX500 Crank / cases issue
« Reply #2 on: November 18, 2019, 09:19:24 PM »
Hello,
Thanks for moving the post.
And thanks for the reply, exactly what I was hoping for - Excellent !!


Kings