KX Riders

Commercially available service offered by members of KXRiders. => OEM-CYCLE => Topic started by: sandblaster on September 01, 2015, 05:52:17 PM

Title: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on September 01, 2015, 05:52:17 PM: We have a 98 KX500 engine in for a full rebuild.
The very first thing we did was to take it outside and wash it...
Nothing worse then working on a dirty engine and contaminating everything as you open her up..

(http://www.oem-cycle.com/forum/download/file.php?id=3473)

Nice pretty blue hose

(http://www.oem-cycle.com/forum/download/file.php?id=3474)

Happens on almost every one of these... :x

(http://www.oem-cycle.com/forum/download/file.php?id=3475)

Everything seemed to be ok until we heard this

https://youtu.be/4Zw9urYXxw0 (https://youtu.be/4Zw9urYXxw0)

Tim, one of these bad boys is for you...

(http://www.oem-cycle.com/forum/download/file.php?id=3544)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on September 01, 2015, 06:04:03 PM: Of course we already ordered our standard list of replacement parts
Seems like this list continues to grow.. :-o

92028 BUSHING 92028-1551
92046 BEARING-NEEDLE 92046-1193
92022A WASHER,22.3X38X3.0 92022-1832
92022 WASHER,22.5X46X2.6 92022-1739
92045 BEARING-BALL,6001C3ML01 92045-1235
92022C WASHER,12.3X20X0.5 92022-269
92022B WASHER 92022-1942
(3) 92045 BEARING-BALL,608MC3 92045-1305
59051 GEAR-SPUR,WATER PUMP,11T 59051-1129
92028 BUSHING,26X35X14 92028-131
92045 BEARING-BALL,6305 92045-1011
92045B BEARING-BALL,63/22T2C3 92045-1134
92045C BEARING-BALL 92045-1233
92045D BEARING-BALL,608MC3 92045-1305
(2) 92046 BEARING-NEEDLE,HK1210 92046-1010
92055-1343 O-RING 92055-1343
(2) 92046-1052 GOVERNOR BEARING 92046-1052
(2) 92045-1027 BEARING 92045-1027
(2) 92055-035 ORING 92055-035
92045-036 BEARING 92045-036
92045-1235 92045-1235
92022-1942 92022-1942
92022 WASHER,17.3X28X1 92022-255
92033 RING-SNAP,24MM 92033-026
(2) 92033A RING-SNAP,18MM 92033-029
(6) 92033B RING-SNAP,25MM 92033-1089
92046 BEARING-NEEDLE,KT202614 92046-1170
92143 COLLAR,25X32X10.5 92143-1370
KICK START SPRING 92081A SPRING    92081-097
(4) 92042-007 PIN DOWEL 6.3 X 8 X 14   92042-00
(5) 610A0408 ROLLER 4 X 8      610A0408
(2) 482J4000 CIRCLIP SELD BEM FIT   482J4000
"0" RING 92055-025
480j2400 cir clip type c 24mm      480j2400
GASKET,EXHAUST PIPE          11009-1949
BOOT                49006-1179
RING-O                92055-035
RING-O,5.5X1.5             92055-1343
RING-O,19.5X1.5          92055-055
(2) RING-O,17.5X1.5          92055-022
(3)               92043-1373

Besides that we are getting some new gears, clutch kit, Squish mods, Team Green mods, Motorrad mods, Pinsonnault Racing crank Balance, Decomp, and perhaps a bit of Port timing advancement.... So we will see what happens on this one as the customer is still undecided how far they want to take it.
And yes, it will be Vapor Blasted to perfection 8-)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on September 01, 2015, 06:06:05 PM: Oh yeah, there's talk of a 2 piece clutch cover but I'm out of adapters right now :x
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: alexander-vmann on September 01, 2015, 06:07:13 PM: that clutch cover crack is nothing compared to the one on my 93 :-D
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on September 01, 2015, 06:09:30 PM: Oh yeah, they can get a LOT worse :lol:
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on September 08, 2015, 01:27:39 PM: We got a bit of lapping done today.
These cases were about the worst we have seen.
Spent almost a hour to get them perfect :-o

(http://www.oem-cycle.com/forum/download/file.php?id=3566)

The head and cylinder were nice to begin with.
They are epic now :lol:

(http://www.oem-cycle.com/forum/download/file.php?id=3567)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on September 09, 2015, 11:34:03 AM: Jason hard at it..

(http://www.oem-cycle.com/forum/download/file.php?id=3568)

Like a surgeon with dirty finger nails :-D

(http://www.oem-cycle.com/forum/download/file.php?id=3569)

Nice work Jason...

(http://www.oem-cycle.com/forum/download/file.php?id=3570)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on September 10, 2015, 07:54:34 AM: Almost ready for plating..

(http://www.oem-cycle.com/forum/download/file.php?id=3583)

(http://www.oem-cycle.com/forum/download/file.php?id=3582)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: DoldGuy on September 10, 2015, 01:19:53 PM: I Spy Exhaust Bridges....

Pics of the ports that have been cleaned up? Did you vapor blast the ports after grinding?
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on September 20, 2015, 10:44:11 AM: Yep... The customer didn't want the exhaust bridges removed.
I told him it was only money :lol:

Yes, we vapor blast them before plating and then again after plating.
We don't really need to vapor blast before plating as the plater sandblasts them but it really helps us see if there are area's that need further work.
Plus is looks really cool 8-)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on October 02, 2015, 01:48:57 PM: Thanks for another good job Todd 8-)

(http://www.oem-cycle.com/forum/download/file.php?id=3641)

(http://www.oem-cycle.com/forum/download/file.php?id=3642)

(http://www.oem-cycle.com/forum/download/file.php?id=3639)

(http://www.oem-cycle.com/forum/download/file.php?id=3640)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: dave916 on October 02, 2015, 11:55:36 PM: Anyone know why todd drills those 4 holes {17mm] in the crank?
Guessing he is using them with some kind of alignment pins for truing the crank/ but i could be wrong
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: alward25 on October 03, 2015, 05:44:42 AM: Balancing with a Wossner rod and piston. Gets the crank to the right balance factor .
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on October 03, 2015, 10:41:45 AM: What balance factor do you use?
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on October 04, 2015, 03:30:54 AM: Ok, that explains a few things.
I know Todd uses 59% for the K5.
Now I'm really gonna step in it here.... :-o
From everything I have researched, it is difficult or almost impossible to cancel out all the forces involved especially on a single cylinder engine.
So, at some point, you have to compromise on all the different forces.
At first thought it seems simple.
Balance the crank, rod, and piston assembly so that if you set the assembly on a balance beam resting on the mains, the crank will not move regardless of the timing just like this video demonstrates:
https://www.youtube.com/watch?v=LzUjXA_aesM (https://www.youtube.com/watch?v=LzUjXA_aesM)

Ready to rip?
Not so fast...
While the assembly is balanced statically, this will do nothing for the other forces involved.
Keeping it really simple and disregarding tertiary forces and such, think about what the piston is doing when it is moving really fast and then it has to change directions.... That's right, we have to factor in acceleration and deceleration of the piston, pin, bearing, rings, and top half of the rod.
To make matters worse, the top 90 degrees of crank rotation happens faster then the lower 90 degrees of crank rotation due to the angle of the rod.
Even if you could totally cancel out all the forced generated by the assembly changing direction at the top 90 degrees of crank rotation, you will then have a imbalance at the bottom 90 degrees of crank rotation.

What all this means is that depending on the balance factor used, the crank asy will vibrate more at certain RPM range then at others.
The object then is to move the major vibration causing imbalance to a rpm range that isn't used.
In the end, 59% seems to be the best compromise for the K5 crank asy....
Let the carnage begin :-D
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: dave916 on October 04, 2015, 07:24:36 AM: The few % on balance factor does not explain the 4 17mm holes near the bigend
If the was the way i could fit a Wossner rod and piston / drill four 17mm holes near the bigend and have fully balanced crank at 59% :-)
Instead of doing all this https://www.youtube.com/watch?v=eZlJi0I80uk
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on October 04, 2015, 08:25:00 AM: Also, the balance holes are different sizes.. :lol:

(http://www.oem-cycle.com/forum/download/file.php?id=1617)

Have you weighed all your components to know where the balance factor is really at?
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: dave916 on October 04, 2015, 09:40:04 AM: All that is double dutch to me :-D
My confusion is how 2 kx500 cranks]can look so differently balanced /weight removed from oppisite side even thought they are balance within a few% :|
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on October 04, 2015, 09:47:40 AM: Without knowing what the exact weight of all the components are we can't calculate.
All we can do is guess...
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on December 07, 2015, 12:34:31 PM: Got the cylinder back from Millennium.
Since they had to weld up the bridges, we had to clean them up.
Then we polished the exhaust..

(http://www.oem-cycle.com/forum/download/file.php?id=3797)

The only thing we are waiting on is the new gears :cry:
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on December 22, 2015, 04:34:03 PM: I just got a call today.... All the gears are in!!! 8-)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on January 01, 2016, 10:40:41 AM: Fresh out of the oven.... Mmmmmmm.... Love that smell 8-)

(http://www.oem-cycle.com/forum/download/file.php?id=3829)

Replaced the shift forks, 6 of the gears including 3rd and 4th input and output.

(http://www.oem-cycle.com/forum/download/file.php?id=3830)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on January 01, 2016, 11:00:30 AM: A little more progress.

(http://www.oem-cycle.com/forum/download/file.php?id=3831)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: Brute on January 01, 2016, 01:07:09 PM: That vapor blasting sure looks nice! Intense project.
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on January 02, 2016, 04:26:23 PM: I have to admit that I am addicted to Vapor Blasting 8-)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on January 05, 2016, 10:30:52 AM: Getting really really close now...

(http://www.oem-cycle.com/forum/download/file.php?id=3832)

(http://www.oem-cycle.com/forum/download/file.php?id=3833)

(http://www.oem-cycle.com/forum/download/file.php?id=3834)
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: umberto on January 05, 2016, 10:47:52 AM: I know I've said this before, but that motor looks like it just rolled off the assembly line. Beautiful work sir.
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: sandblaster on January 05, 2016, 12:52:11 PM: Thanks.
My engine builder Jason takes a lot of pride in his work and it shows.
I wish people would spring for some nice stator covers...
I really wish someone would make a nice stator cover :roll:
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: umberto on January 05, 2016, 01:11:20 PM: I agree 100 percent. It makes me sad to look at the one on my motor. I'm springing for another couple of goodies, so the cover will have to wait.
Title: Re: 1998 KX500 ENGINE BUILD For Tim
Post by: swordcombat on January 06, 2016, 04:30:51 AM: Quote from: sandblaster on January 05, 2016, 12:52:11 PM
Thanks.
My engine builder Jason takes a lot of pride in his work and it shows.
I wish people would spring for some nice stator covers...
I really wish someone would make a nice stator cover :roll:

What about Topar racing , wouldnt they make nice billet one