Maintenance & Technical > KX500 Original
Complete KX500 top-end rebuild instruction here!
KXcam22:
John,
The format looks great. I would suggest I might be handy to embed the photos and convert it to a .pdf. The main advantage of this is that you can save and print the whole thing off in one document. I am doing my top end right now so I eagerly await and details and tidbits. The piston chamfer idea is really good. Never done that before and my new Wiseco is sharp as a razor. I also noticed one other port area on my barrel that needs attension. Inside the main transfers at the base gasket area, exhaust side, inside of where the nut goes on outside to bolt the barrel down. Mine ('92) has a bulge inside to give thickness to the outside transfer wall but this directs the flow away from the transfer wall. I had to carve a bit away to make the outter port wall smooth. Thanks. Cam.
demographic:
--- Quote from: KXcam22 ---John,
I would suggest I might be handy to embed the photos and convert it to a .pdf. The main advantage of this is that you can save and print the whole thing off in one document.
--- End quote ---
That's a very good idea.
I have been trying to get together a collection of PDF bike manuals for a while now so having some KX info on file would be most usefull.
doordie:
Hi Folks!
I will remind you about the squishclearance. :wink:
You can search for it here in forum and found out why it?s so importent.
As a rule: NOT below 1.3 mm, and you can chim off the head or buy
different thickness of headgasket.Only check what compression you have
when mods done ,so you not use wrong gasoline oktantype. :wink:
John asked about how much power this mods in barell will do and with right squishclearance, I will say 10% overall power and no "pinging". :twisted:
//doordie
John:
OK, got my cylinder back and the (Doordie / John) instruction is complete. Check out http://www.hallbergs.net/kx500/
I hope this is useful information, it has been for me. Unfortunately, I have made too mane modifications at the same time to be able to tell which one made the biggest difference. The end result is that my engine performs REALLY well!
FYI. I will be zipping it all up for offline access. I have not decided the format yet.
Feedback and questions are welcome, use the Pitbull forum or the email address on the web page.
The reason why I have made the effort to document this is; because I can, not because I am a particularly skilled two stroke mechanic and actually know what I am doing. Doordie on the other hand knows a lot about tuning two strokers and the KX5 in particular.
Good luck with your own rebuild!
//John
John:
OK.
The squish can easily and accuratly be meassured with solder. A couple of people have told me this but it did not work for me. The reason it didn't work is that the solder I have is 0.2 mm in diameter. It does work if you use the really thick solder (petrol stations quality) - not the proffesional stuff for surface mounted PLC circuits. It all made sense to me when I went to the local car repair shop and noticed the solder thay use (>2mm).
You guys who have given me feedback about this - sorry for being so thick.
//John
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