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Author Topic: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN  (Read 26961 times)

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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #15 on: February 29, 2016, 03:00:27 AM »
So your all ready for the big moment.... And what's gonna happen?
Watch the master at work  :-o

https://www.youtube.com/watch?feature=player_embedded&v=0JEPlaw_ZU8

Ok, so the crank is in and that's the easy part... Watch the master install the other case half..

https://youtu.be/Wp9g4RDLnow

Easy peasy  :-D
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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: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #16 on: February 29, 2016, 03:00:55 AM »
Now it's time to install and torque the case bolts.

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

Offline LukeG

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #17 on: February 29, 2016, 05:42:53 AM »
That easy bake oven makes life easy!
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1990 KX250 - Wanna be road racer!
2007 DRZ 462 Motard

Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #18 on: February 29, 2016, 07:03:00 AM »
It sure helps  8-)
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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: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #19 on: March 12, 2016, 06:58:28 AM »
Since we are waiting for the custom ported cylinder to get back from Milennium Tech Jason went ahead and rebuilt the clutch basket with a new basket 8-)

It turned out sweet...



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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: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #20 on: March 18, 2016, 11:56:33 AM »
A tip from Alward25, dimple the bolts to help prevent them from backing out..

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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: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #21 on: March 18, 2016, 11:59:41 AM »
Ok... so Kevin purchased a VF2 reed from me so I told him I would do all the boot mods for free.

Here we go..

Stock boot..



Ears are removed and sanded flat..



Now whip out the VForce 3 reed and stuffer..... What???  :? :? :?



Yes... Put the VF3 in there with the stuffer..

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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: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #22 on: March 18, 2016, 12:01:01 PM »
Now put some silicone of some type on the stuffer only...



Now install the boot...



Let it dry over night



Reach in there and feel around with your finger... You will understand why I do this mod..
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Pmcg

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #23 on: March 18, 2016, 11:12:47 PM »
Your motors look so good. I need a vapor blaster
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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #24 on: March 19, 2016, 02:37:20 AM »
We all need a vapor blaster  :lol:
If I was starting all over again it would be one of the first things I would buy.
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Foxx4Beaver

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #25 on: March 19, 2016, 02:48:28 AM »
Quote from: sandblaster on March 19, 2016, 02:37:20 AM
We all need a vapor blaster  :lol:

absolutely!....my KX's, the KZ, my sled, and my trucks would all look totally different if I had one!...so amazing the transformation from "before & after".   
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Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Motorrad

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #26 on: March 19, 2016, 03:03:05 AM »




Reach in there and feel around with your finger... You will understand why I do this mod..


I hope you bought it dinner first
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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #27 on: March 19, 2016, 11:51:46 AM »
After the goop has set up, carefully remove the boot and take a look at what you have..
Note the difference in the boot hole VS the stuffer hole..



Clean away the excess goo without breaking the stuffer from the boot.. Then get a marker and mark the boot.



Now remove the stuffer from the boot and see what you have..

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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: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #28 on: March 19, 2016, 11:52:40 AM »
That yellow profile need to go away..
The first time I ever did one of these I used a small sanding drum on a Dremel.
My tools have improved somewhat since then...



It's still a little rough but you get the idea..



Now you can compare the VF3 stuffer and make sure that you didn't miss anything...
NEXT!!!!   :-D
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Offline Foxx4Beaver

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #29 on: May 03, 2016, 07:54:24 AM »
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Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ
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