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Author Topic: 91 kx500 engine disassembly and inspection  (Read 21324 times)

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Offline sandblaster

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91 kx500 engine disassembly and inspection
« on: June 04, 2015, 12:47:13 PM »
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline MRDART

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Re: 91 kx500 engine disassembly and inspection
« Reply #1 on: June 04, 2015, 07:10:46 PM »
Interesting... Never seen such damage before...
 Seen the seal spin (clutch side) on my old kx500 back in 93-94 sometime...
Welded and grinded back to size/alignment, but thats a different story...
 New /used case is the Quick way to go..., but it is fixable in a mashineshop, so don't throw it away please :-)
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #2 on: June 04, 2015, 07:45:35 PM »
Quote from: MRDART on June 04, 2015, 07:10:46 PM
but it is fixable in a mashineshop, so don't throw it away please :-)

Never... I have several bad ones that I am saving for a rainy day  :mrgreen:
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #3 on: June 09, 2015, 01:32:41 PM »
When we are done it will look like this one were started working on today..



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Offline chaelvick

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Re: 91 kx500 engine disassembly and inspection
« Reply #4 on: June 09, 2015, 02:45:28 PM »
Thanks for the good info sandblaster
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Offline dave916

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Re: 91 kx500 engine disassembly and inspection
« Reply #5 on: June 10, 2015, 03:35:14 AM »
Quote from: sandblaster on June 09, 2015, 01:32:41 PM
When we are done it will look like this one were started working on today..




Sandblaster are them extra holes in the crank done by the crank people ?
89on cranks dont have alignment holes?
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #6 on: June 10, 2015, 03:37:37 AM »
Yep... After market... Thank you Pinsonnault Racing  8-)
Wossner rod which is a little hard to see in these pics.
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Offline dave916

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Re: 91 kx500 engine disassembly and inspection
« Reply #7 on: June 10, 2015, 06:08:09 AM »
What % were they balanced at?, My cranks  seem to have metal removed from opposite side, finding it hard to understand why the drill big holes like that?

eg
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #8 on: June 10, 2015, 12:36:01 PM »
59%
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #9 on: June 16, 2015, 12:28:07 PM »
Crank half is done.



The company I had repair it had to grind it undersize then plate it, then grind it to the finish size...
Perfect!  8-)
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Offline edgar_kx3

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Re: 91 kx500 engine disassembly and inspection
« Reply #10 on: June 16, 2015, 01:24:33 PM »
does it hurt to have them ground so its more like a slip fit, throw some retaining compound on it when going together? make putting the halfs together so much easier.
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #11 on: June 16, 2015, 01:39:45 PM »
First, it is ground to cleanup, then, it is plated oversize so that when they grind it, they grind it to the factory finish size.
Just for grins I checked the fit and it is perfect.
Gotta like that  :mrgreen:

The current cost is 75 USD to have one repaired but you have to have it pressed apart first..
« Last Edit: June 16, 2015, 01:41:26 PM by sandblaster »
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Offline alward25

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Re: 91 kx500 engine disassembly and inspection
« Reply #12 on: June 17, 2015, 01:57:07 AM »
Is that at the place across they alley 'Blaster?
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #13 on: June 17, 2015, 02:27:46 AM »
Yep
But if you walk in the door you won't get it done for that price  :wink:
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #14 on: June 24, 2015, 07:56:33 PM »
The case is at the plate shop along with the bearing for the correct interference fit.
Here's their main tank.



The plater said the case had too be EXTREMELY clean before he would put it in his tank



I think we did a ok job :lol:
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
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