2000 KX500 Project

[Pmcg]

Yea sorry the rod that comes out of the cylinder. I replace the seal and it still leaks so I got a new rod. Hopefully that fixes it.

[Pmcg]

So for anyone with the same vacuum issues I solved it with a new KIPS rod Part#49046-1064 (mine was bent) I also had to replace the valve guide Part#49002-1062 The oil seal part #92049-1206 and the o-ring Part#92055-025.  Probably worth ordering all 4 right out of the gate if you're having the same issue. 

Bent Rod


Valve guide and the bad o-ring

[Motorrad]

nearly all used rods leak...   that I have seen

[Pmcg]

nearly all used rods leak...   that I have seen

I really would have bet against it being the rod.  Luckily you posted your findings or id still be working with it.  I do have a leak around the reeds despite new gaskets so I think I need a new boot as the old one has a bit of cracking but I think I'm going to need to put it in with yamah bond.  any suggestions?

[Motorrad]

My order of installation

Yamabond
Cometic  gasket
Yamabond
Reeds
Yamabond
Comedic gasket
Yamabond
Intake boot

[alward25]

New boots looked cracked, not sure of their process, not the smoothest, as long as you can't see any cracks on the inside.  Good to go

[Pmcg]

Any advice on removing the power valve bearing from the clutch cover?  My puller is to big (I don't run into that issue often) and I had 1 made smaller but it just bent.

[sandblaster]

Heat and a blind bearing puller gets 99.99% of them out.

[Pmcg]

So my new issue is that the oversized Clarke tank hits my compression release valve. I'm considering heating and bending the tank around the release but terrified of ruining my new tank. Anyone have advice on bending?  I'm also considering trying to trade for a tank that will fit but am not sure what oversized tanks work.

[Pmcg]

So heat gun and a pipe?

[sandblaster]

Just be careful with the heat gun.
I have melted clear through one tank.
I have heard that boiling the tank works well but I have never tried it,

[Pmcg]

Im rebuilding the clutch cover now and knew that the motor had blown a water pump seal so I ordered a new seal but on inspection the water pump gear spur had a good bit of galling/scoring so I ordered a new one.  I bet it gets overlooked all of the time. 

[Motorrad]

Very common problem in KTM lc4 motors

[Pmcg]

Does anyone make a jet kit that comes with a few different jets or is my best bet to buy them individually? 

[Pmcg]

So it looks like I'm just going to order a bunch of individual jets from jets r us. Any recommendations on where to start?  I'm planning on ordering a few options. Bike is 88mm vf2 and pro circuit pipe at 900 ft. And advice is appreciated.