2000 KX500 Project

[reklessj]

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  

[Pmcg]

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  

You lost me at 30x30!!!!

[reklessj]

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!

[Pmcg]

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

[Brute]

Need to leak test mine too but am afraid it would add another year to the build! Glad you found the leak! Lookin' good!

[Pmcg]

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.

[Pmcg]

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. 

[Pmcg]

Almost tackled the UPS guy today

[sandblaster]

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?

[Pmcg]

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.

[sandblaster]

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... 

[Pmcg]

No problem.  I will scan and email it to you as well.  Whats the best way to rotate the motor clockwise?

[Pmcg]

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!!!!

[Foxx4Beaver]

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.

[Foxx4Beaver]

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.