Maintenance & Technical > KX500 Original

Complete KX500 top-end rebuild instruction here!

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John:
Scott,

Thanks (and on the behalf of Doordie as well). Have added your feedback and some other stuff as well. There will be a more complete update once I get my cylinder back from the re-plating. Then again, I will probably be out riding and not have any time for this...

The power valve fix amongst other things are Doodies work, I merely documented it whilst doing it on my machine.

The whole idea behind this is to assist others who also shares the KX500 passion. All this information exists on the Internet (and some does not) but is rather scattered. The goal is to have a complete rebuild instruction including tweaks. I rather be beaten by a KX5 than any other machine. So it's in my own interest to see that they all work fine!

I don't know what these mods will do to my machine other than making it better. I probably can expect some additional HP, but not much. Maybe Doordie has an idea?

//John

gowen:
John, excellent write up! Very detailed and easy to read. The pictures are great too.

demographic:

--- Quote from: John ---Scott,

Thanks (and on the behalf of Doordie as well). Have added your feedback and some other stuff as well. There will be a more complete update once I get my cylinder back from the re-plating. Then again, I will probably be out riding and not have any time for this...

The power valve fix amongst other things are Doodies work, I merely documented it whilst doing it on my machine.
--- End quote ---


I will be sorting out the powervalve when I next do some work on it so should be able to provide better feedback then, I have just had a quick look at the page so far and untill I have the cylinder in my hands it's hard to tell how much will be relevant to me.






















Might be getting the files out though :D

Regards Scott

KXcam22:
John & Doordie,
  That is excellent!  I really like the photos.  As a suggestion for some additions, It might be helpfull to have a section on cylinder surface prep, a torque chart for the top end nuts and bolts, a guide on how to assemble the KIPPS so the opening time is correct.  The big end rod radial clearance (rather large) answered lots of my questions.  I recently took my crank in to have a new rod put in since I could get mine to "clink" up and down. My past rule of thumb was that any perceptible movement meant it was shot. The Kawi dealer laughed and sent me home.  Now I see why.  Good work guys. Cam.

John:
Thanks,

This will be more complete once I get my cylinder back. I will then get the last pieces together (with the help of Doordie).

Question; is the format OK or should I add the pictures into the page (togther with the text). I am thinking about also zipping it up so people can download it so you do not have to be online all the time. I will add reference-ID's for each picture and reference the pictures in the text, ie. see picture 3.

Any ideas?

I will contact Paul once he is back and see how this information can be migrated into the forum (should he want to). I do not want the resposibility of maintaining this for ever...


//John

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