Author Topic: 2000 KX500 Project  (Read 113327 times)

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Offline reklessj

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Re: 2000 KX500 Project
« Reply #180 on: May 24, 2014, 01:30:28 AM »
I bent over quick today to grab a wrench and got penetrated by a Suzuki jr50 so I had to put everything on hold and try to arrange my garage. It's like trying to stuff 15 lbs of flour in a 10lb sack.

[img][/imghttp://i1052.photobucket.com/albums/s450/the7knolls/Mobile%20Uploads/NCM_0299_zpsd6f54e44.jpg
That garage space is nothing!!  30×30 garage crammed with a sea Doo XP on stand, 1998 zxi1100 & 1995 zxi900 on trailer, 1986 LT230, 1986 XR250R, 1992 LT250R, 1988 TECATE 4, 1992 LT80, 1998 DS80, 2002 RM250, 2004 105SX, 1995 YZ125, AND 1994 KX500. guess you could say  a hoarder :lol:  :lol:
My rides: 1994 KX500, 1988 T4, 1998, ZXI 1100 JETSKI, 2003 MOUNTAIN CAT 900
WIFES (Baby Fiver) rides: 2004 KTM 105SX,1992 LT250R, 1995 ZXI 900 JETSKI,  2011 RMK 600
SONS ride: 1995 YZ125,2002 RM 250
other rides: 2007 RMZ450 RC Ediition, 2003 RMK700

Offline Pmcg

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Re: 2000 KX500 Project
« Reply #181 on: May 24, 2014, 01:08:26 PM »
I bent over quick today to grab a wrench and got penetrated by a Suzuki jr50 so I had to put everything on hold and try to arrange my garage. It's like trying to stuff 15 lbs of flour in a 10lb sack.

[img][/imghttp://i1052.photobucket.com/albums/s450/the7knolls/Mobile%20Uploads/NCM_0299_zpsd6f54e44.jpg
That garage space is nothing!!  30×30 garage crammed with a sea Doo XP on stand, 1998 zxi1100 & 1995 zxi900 on trailer, 1986 LT230, 1986 XR250R, 1992 LT250R, 1988 TECATE 4, 1992 LT80, 1998 DS80, 2002 RM250, 2004 105SX, 1995 YZ125, AND 1994 KX500. guess you could say  a hoarder :lol:  :lol:

You lost me at 30x30!!!!

Offline reklessj

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Re: 2000 KX500 Project
« Reply #182 on: May 24, 2014, 06:08:49 PM »
I got all that stuff shoved in a 30ft by 30ft garage!! Throw a lil KY on them bars and it won'tbother you as much! :lol:
My rides: 1994 KX500, 1988 T4, 1998, ZXI 1100 JETSKI, 2003 MOUNTAIN CAT 900
WIFES (Baby Fiver) rides: 2004 KTM 105SX,1992 LT250R, 1995 ZXI 900 JETSKI,  2011 RMK 600
SONS ride: 1995 YZ125,2002 RM 250
other rides: 2007 RMZ450 RC Ediition, 2003 RMK700

Offline Pmcg

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Re: 2000 KX500 Project
« Reply #183 on: May 27, 2014, 07:05:05 PM »
Good weekend for me.  I got all the s**t back in the elephant


Got the tank bent with no hole


Found my air leak.  It was in the kips bolt.  Not sure how I missed it. 

Ran the carb through the ultra sonic and put in the new jets and seals



And topped it all off with a little redneck engineering.  Here's my peg bracket straightener

Offline Brute

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Re: 2000 KX500 Project
« Reply #184 on: May 28, 2014, 04:04:26 AM »
Need to leak test mine too but am afraid it would add another year to the build! Glad you found the leak! Lookin' good!
Things Are More Like They Are Today Then They Have Ever Been Before...

Offline Pmcg

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Re: 2000 KX500 Project
« Reply #185 on: May 28, 2014, 04:25:51 AM »
Need to leak test mine too but am afraid it would add another year to the build! Glad you found the leak! Lookin' good!

Thanks. I built my own leak tester let me know if you'd like to borrow it and ill send it out.

Offline Pmcg

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Re: 2000 KX500 Project
« Reply #186 on: June 01, 2014, 03:24:05 AM »
I installed a new water pump seal in the clutch cover and as a bit surprised at how hard it was to turn the water pump spur gear. It's pretty straight forward don't think it possible to mess up but I'm a bit worried it will get hot and melt the seal. Any experience with these?  Thanks Pat. 

Offline Pmcg

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Re: 2000 KX500 Project
« Reply #187 on: August 05, 2014, 03:42:30 PM »
Almost tackled the UPS guy today

Offline sandblaster

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Re: 2000 KX500 Project
« Reply #188 on: August 05, 2014, 04:05:18 PM »
Oh yeah... I pulled my MZB out of the box...
I'm ready to install mine next week.
Did you talk to Alex about what to watch for?

On the pump, it should not be too tight.
Did you lube the seal lip when you installed?
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Pmcg

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Re: 2000 KX500 Project
« Reply #189 on: August 05, 2014, 04:32:04 PM »
I spoke with Alex but don't remember any specific things to watch for.  Anything I need to look out for? Also no lube on the seal. I figured coolant and case oil would keep it spinning.

Offline sandblaster

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Re: 2000 KX500 Project
« Reply #190 on: August 05, 2014, 06:08:55 PM »
I'd give it some asy lube just for grins...

I don't have my notes but here goes from memory...
Lap the flywheel.
Dial indicator through the spark plug hole and zeroed out at TDC.
Rotate the motor clockwise which is reverse to how it runs till you hit .087" then set the line on your flywheel to your dot on your stator.
Then rotate your engine a full 360 degrees. When you hit .087", check the alignment again to make sure the marks still line up.
Torque the flywheel nut and triple check.
Run all ground lines to the same spot on the frame such as where your coil bolts on.
Check your battery voltage, then start your bike and check the voltage again to be sure it is charging the battery.
Alex... Please double check this.
Since you have the directions, could you take a pic of section 2 and 3?
For some reason mine is gone.
I'd like to have it for my records.
I tried to download it from their sire but the directions don't match up...  :oops:
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Pmcg

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Re: 2000 KX500 Project
« Reply #191 on: August 05, 2014, 06:38:51 PM »
No problem.  I will scan and email it to you as well.  Whats the best way to rotate the motor clockwise?

Offline Pmcg

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Re: 2000 KX500 Project
« Reply #192 on: October 05, 2014, 12:27:57 AM »
Slowest project ever has hit another snag.  I'm running an RK GB520EXW chain with Supersprox but am getting a little chain rub on the case.  Obviously I dont want to destroy the case.  I was told the chain wold work anyone use this chain?  Is a little rub ok?  I am spinning the back wheel while the bike is on a stand so that changes the angle a bit but the rub is freaking me out.   Thanks guys!!!!



Offline Foxx4Beaver

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Re: 2000 KX500 Project
« Reply #193 on: October 05, 2014, 12:37:50 AM »
yup, I had a slight rubbing issue a few years ago....then I switched to the RK MXU-Ring chain...it's much narrower and lighter...and no where near the case...


it's still an o-ring...but the O-rings are almost flat and ribbed.
« Last Edit: October 05, 2014, 12:57:51 AM by Foxx4Beaver »
Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Offline Foxx4Beaver

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Re: 2000 KX500 Project
« Reply #194 on: October 05, 2014, 12:54:38 AM »
the other thing I discovered was that when I got my bike a few years ago, it had a Sunstar front sprocket on it...switching to a Renthal sprocket pushed everything out away from the case a touch more too.
Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ