Commercially available service offered by members of KXRiders. > OEM-CYCLE
Sean Colliers KX500 Project "I was only going to inspect the top end"
dave916:
--- Quote from: sandblaster on October 30, 2016, 01:07:14 PM ---Good call.
I'd love to see someone turn that engine over with no kick lever :lol:
--- End quote ---
Its easy to stick on a kicklever when refitting the motor [Takes a few seconds}
People love to see what compression a new motor has
Checking for spark is another reason
sandblaster:
Wrapping up this build is a bit scary.
Oscar is assembling the bike down in S. Cal.
He should be able to put some heat cycles on it and ride it on Friday to break it in.
Sean races on Saturday :shock:
What we did to this engine to freshen it up was not what we wanted to do.
It was all we were allowed to do.
I saw a lot of room for improvement but that was just the point.
They didn't want any improvements other then longevity and better shifting.
I will get more into that later.. Cool things are coming 8-)
But here is the basic list:
Disassemble, clean, and carefully inspect EVERYTHING.
Vapor blast all the aluminum, and polish everything that could be polished, head, trans gears, trans shafts, ect.
Replaced all the shift components with used but in spec parts.
All were hand polished.
Replaced the clutch plates.
Hand ground the dogs on the trans gears.
Replaced the piston and Ring set with a very low hour set from my own bike.
Every bearing, seal, and gasket, was replaced.
Hand filed the clutch basket ears and the clutch hub, then polished them.
The left engine case was replaced as the existing one was junk.
Hand lapped the cases, cylinder, and head.
Disassembled the carb, cleaned it thoroughly, reset the floats, and set the screws to how they were when we received it.
It really could have used a plate job but we just didn't have the time or the money to do it.
Also, some of the gears were pretty poor but I think after Jason tuned them up they should be ok for a while.
So, it wasn't what we would have liked to do but it should survive until we get Sean's new bike built.
Now it's time for Oscar and Alex to chime in with what they did..
Brute:
"Wrapping up this build is a bit scary.
Oscar is assembling the bike down in S. Cal.
He should be able to put some heat cycles on it and ride it on Friday to break it in.
Sean races on Saturday"
Gee, nothing like cutting it close! :-o
Hope all goes well. Looked nice!
alward25:
--- Quote from: sandblaster on November 01, 2016, 04:04:53 PM ---Wrapping up this build is a bit scary.
Oscar is assembling the bike down in S. Cal.
He should be able to put some heat cycles on it and ride it on Friday to break it in.
Sean races on Saturday :shock:
What we did to this engine to freshen it up was not what we wanted to do.
It was all we were allowed to do.
I saw a lot of room for improvement but that was just the point.
They didn't want any improvements other then longevity and better shifting.
I will get more into that later.. Cool things are coming 8-)
But here is the basic list:
Disassemble, clean, and carefully inspect EVERYTHING.
Vapor blast all the aluminum, and polish everything that could be polished, head, trans gears, trans shafts, ect.
Replaced all the shift components with used but in spec parts.
All were hand polished.
Replaced the clutch plates.
Hand ground the dogs on the trans gears.
Replaced the piston and Ring set with a very low hour set from my own bike.
Every bearing, seal, and gasket, was replaced.
Hand filed the clutch basket ears and the clutch hub, then polished them.
The left engine case was replaced as the existing one was junk.
Hand lapped the cases, cylinder, and head.
Disassembled the carb, cleaned it thoroughly, reset the floats, and set the screws to how they were when we received it.
It really could have used a plate job but we just didn't have the time or the money to do it.
Also, some of the gears were pretty poor but I think after Jason tuned them up they should be ok for a while.
So, it wasn't what we would have liked to do but it should survive until we get Sean's new bike built.
Now it's time for Oscar and Alex to chime in with what they did..
--- End quote ---
Well, not much....I am one heck of a cheerleader. Sandblaster took this thing on full bore and put a lot of time and money into something we were not patient enough to wait for pledged outside money and support. Hats off to Sandblaster and USMC500 for all the work.
I overhauled the rear shock and revalved it. New Pro Action Valve, Seal head assy, bumper, and bladder. Serviced with only the best year nitrogen and Amsoil 5 wt shock therapy oil. I also provided a complete Cometic gasket set with the base gasket cut with the small KIPS drum holes.
Can't wait to see how this thing will rip!!!!
sandblaster:
Everybody involved contributed.
KX Guru Racing is not a Company, Corporation, Entity, or Individual.
It's a collaboration of guys that love the KX500 and want to see it continue being rode and improved for years to come.
And a lot of what we did was inspired by members of this forum.
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