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Project Roached-Out KX60

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diesel:
Last fall, I picked up a '99 KX60 with a rotten engine.  My son was pretty excited about the project, but working two jobs kept me from working on the bike as much as I wanted to.

I pulled the engine, recovered the seat, and installed a new rear knobby over the course of several weeks.  Then I picked up a complete Wiseco bottom-end kit and started the process of splitting the cases.  Then the project stalled.

I finally decided to buy an engine off of eBay (which I've only done once before with disastrous results).  After waiting three weeks, the poorly packaged engine finally arrived.  Although I specifically asked the seller to take their time with the packaging, the engine was just sitting loosely in a cardboard box when it arrived.  With the engine rolling around in the box (along with the sparkplug, shifter, and kicker) the engine ended up with case damage.  My blood pressure spiked...

Today I bead blasted the crud-covered pipe, only to find numerous cracks near the mounting tab and baffle cone.  I just can't win.  My son's birthday is Friday and I won't have the bike done as planned.

Thanks for letting me vent.

Coop:
Do you not know how to split cases or was there another problem?

I have a stock pipe you could have.  It's banged up back by the silencer, but if it will help you are welcome to it. No cracks that I saw when I sanded and painted it. Just the previous owner smash it to clear the after market shock reservoir.

I have a manual if you have questions or I have a few .pdf's (including a complete KX65 .pdf manual which pretty much shares the same bottom end as our 60's).

jonny500:
dont give up. why not put some pics on here im sure we can come up with some solutions. may be not on schedule

diesel:
I have a Clymer manual and a pretty good arsenal of tools.  I don't have a case-splitter, but in my experience with the Honda TRX250R, a dead-blow hammer is all that's needed.  My problem is simply a lack of spare time to work on the bike.  I really didn't want to buy an eBay engine, but my son will have outgrown the bike by the time I get the original engine rebuilt.  It's bad enough that he's lost all enthusiasm for the project...but ten months of waiting will do that to a kid.

Friar-Tuck:
 Jinkies Diesel,
  Where are you located?
 Maybe someone near by could give you a hand.   Dollars to dognuts that kid will love riding...
  You could send the engine to me but you're looking at the same time table problem and I could only buy parts as budget would allow. 
  Oh yea, I do have a case splitter if you need it. last guy I shipped it to cost about $15.00
I have been very fortunate send out and receiving my stuff back, only got burned once...
   Tuck\o/

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