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Author Topic: 2001 KX500 Kawasaki Supermoto  (Read 325952 times)

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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #465 on: May 13, 2014, 04:28:59 PM »
My seals didn't come in but, something else good showed up today..

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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #466 on: May 14, 2014, 05:43:30 PM »
Out with the old...



YES!!!!! STICKERS!!!!

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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #467 on: May 15, 2014, 09:58:33 AM »






Lot's of clean up is required...
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #468 on: May 15, 2014, 03:31:30 PM »
I like this part of the directions..



I have no idea what I'm doing but I never let that stop me  :?
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Motorrad

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #469 on: May 15, 2014, 03:34:54 PM »
Quote from: sandblaster on May 15, 2014, 03:31:30 PM
I like this part of the directions..



I have no idea what I'm doing but I never let that stop me  :?

My favorite answer I use all the time when I'm asked if I can fix something.

"I've never had one give me trouble before"
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #470 on: May 15, 2014, 03:43:41 PM »
Good one.
I'll keep that for later use  8-)
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #471 on: May 16, 2014, 05:26:17 PM »
After a bit of head scratching, a phone call to Race Tech, and this diagram:



I finally got the order and size of the shim stack for each stage of rebound and compression.
« Last Edit: May 16, 2014, 05:30:48 PM by sandblaster »
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Offline alward25

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #472 on: May 16, 2014, 05:33:02 PM »
you would not have had this problem if you had me do it :-D
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"Let there be light"

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #473 on: May 16, 2014, 05:56:59 PM »
True, but what's the fun in that  :-P
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #474 on: May 19, 2014, 02:35:37 PM »
So, I decided to put my two piece clutch cover on and start test riding it to make sure it will hold up for the long haul.
After thoroughly cleaning the inner clutch cover up, installing new bearings and seals, and installing the governor rod, governor, ect I tried to install it and discovered a problem.
The main KIPPS shaft was stuck.
I tried to move the shaft but it was really stuck.
I next pulled the pipe off and looking into the cylinder... Sure it was locked up but I couldn't see why?
So i pulled the cylinder off and now the lever works fine... WHAT????



Nothing unusual here... Although it might be running a bit lean..



Over all, I'm happy with how everything looks so where is the problem?
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #475 on: May 19, 2014, 02:36:14 PM »


Again, nothing out of the ordinary..

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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #476 on: May 19, 2014, 02:37:07 PM »
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #477 on: May 19, 2014, 02:38:14 PM »
Then, I found the problem...
When I put a little pressure on this valve guide, the KIPPS stop moving.



I put a straight edge over the other valve guides and this is the only one sticking up about .002" above the surface of the cylinder base.
So, I grabbed a cylinder I've had sitting on the shelf for a while, put it on the engine and it works perfectly.
With my thoughts verified I decided to install the new cylinder, a new Wossner windowed piston, a new Larry modded head with compression release, and re-jet my carb.
Oh yeah, and install my 2 piece clutch cover...

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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #478 on: May 19, 2014, 02:40:18 PM »
KIPPS move smoothly once the inner clutch cover is installed, Check



Water pump impeller clearance mod... Check



Everything bolted and torqued to factory specs, check.

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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #479 on: May 19, 2014, 02:41:39 PM »
I should be able to start heat cycles tomorrow..  8-)
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