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Author Topic: 91 kx500 engine disassembly and inspection  (Read 21196 times)

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Offline umberto

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Re: 91 kx500 engine disassembly and inspection
« Reply #15 on: June 25, 2015, 03:39:23 AM »
Man, that brings back memories.  My dad owned a chrome shop when I was a kid, and I can still remember the smell of those chemicals.  I don't know how those guys do it today.  The EPA pretty much ran my dad's place out of business with all the new regulations.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #16 on: June 25, 2015, 07:24:30 AM »
1.5 million in pollution controls, constant monitoring and compliance with all the codes.
The foreman spends more time filling out the papers then he does working on parts.
It's crazy..
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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 #17 on: June 25, 2015, 09:24:50 AM »
Off to Pinsonnault Racing for the full treatment...

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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Bigbodybiker

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Re: 91 kx500 engine disassembly and inspection
« Reply #18 on: June 27, 2015, 07:56:24 PM »
Got my mouth watering...
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #19 on: August 10, 2015, 02:29:20 PM »
Welcome to our case lapping shop.
Notice how when we first start the edges are dark gray and the center is yellow?
That's because the outside edges are making contact but the inside of the cases are not.
Can you say Air Leak?
We knew you could!!! :D



After 10 minutes on the lapping machine you can see that there is more dark grey...
But still there is that persistent yellow in the middle.



After about 20-25 minutes total we are getting a nice consistent dark grey all the way around... Success!!



Meet my lapping machine... His name is Jason :lol:

« Last Edit: August 10, 2015, 02:37:39 PM by sandblaster »
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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 #20 on: August 10, 2015, 02:30:17 PM »
Enlarging and chamfering the main bearing oil passage for better lubrication..



Now for some oil passage massaging at the porting table..

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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 #21 on: August 13, 2015, 01:27:24 PM »
All new snap rings, bushings, and collars.
Clean too..



Before



After



Before



After

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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 #22 on: August 18, 2015, 03:06:02 PM »
As if it weren't clean enough already...





Assembly has started

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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 #23 on: August 18, 2015, 03:14:39 PM »
Next thing you know I'll have to wear a hair net and white gloves around the shop instead of what I usually wear...

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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline cmotodad

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Re: 91 kx500 engine disassembly and inspection
« Reply #24 on: August 18, 2015, 06:29:22 PM »
When enlarge and chamfer the main bearing holes in the case. What size do you drill to? Thanks
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Offline LukeG

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Re: 91 kx500 engine disassembly and inspection
« Reply #25 on: August 18, 2015, 08:31:05 PM »
I'm curious about that too. I pulled out the 250 cases on the weekend to see what size the holes were, about 4mm, so I grabbed a lathe centre drill and counter sunk the tops of the holes then used a 6mm drill to open the holes up then using a die grinder chamfered the bottom of the holes to blend into the castings better.
What's the oil passage grinding being done?
Thanks
Luke
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1990 KX250 - Wanna be road racer!
2007 DRZ 462 Motard

Offline ecdeyzel

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Re: 91 kx500 engine disassembly and inspection
« Reply #26 on: August 18, 2015, 09:55:42 PM »
Quote from: sandblaster on August 18, 2015, 03:14:39 PM
Next thing you know I'll have to wear a hair net and white gloves around the shop instead of what I usually wear...



LOL, you can make and sell food on the side while working on your motors.  :-D

Ed
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1999 Kawasaki KX250 (Rebuild in Progress)

Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #27 on: August 19, 2015, 02:48:59 AM »
Quote from: cmotodad on August 18, 2015, 06:29:22 PM
When enlarge and chamfer the main bearing holes in the case. What size do you drill to? Thanks

I use a 6mm drill then a low speed countersink.
I only do this with the KX500 and some older KX250's.
The KX250's I forget what size I use but it is the same as the newer KX250 cases.

Quote from: ecdeyzel on August 18, 2015, 09:55:42 PM
LOL, you can make and sell food on the side while working on your motors.  :-D
Ed

Look below my right elbow.
You will see some Chef Merito Carne Asada seasoning  :-D
« Last Edit: August 19, 2015, 02:53:38 AM by sandblaster »
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline cmotodad

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Re: 91 kx500 engine disassembly and inspection
« Reply #28 on: August 19, 2015, 02:57:49 AM »
Thank You sir. for all the great advice and info.
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #29 on: August 19, 2015, 03:01:56 AM »
Thank Motorrad.
He has shared a wealth of info on this site and I recorded most of it  :-o
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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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