New to the site from New Hampshire

[dirtridernh]

Hello all,


  Project 91' KX500 I'm finally getting to this year. Getting ready to tackle the bottom end rebuild but could use some help on what to replace. I have new crank bearings and seal and a connecting rod. I'm looking to do all the transmission bearings and any other bearings in the bottom end and if there is anything else I should do? Looking to do this right the first time and probably will never have to do this again since I'm setting this bike up to use o the ice only. Any links too on this site to find bottom end stuff would be helpful. I'm also was thinking to have the crank welded and balanced since I'm going this deep into it.

[Foxx4Beaver]

welcome dirtridernh!

I'd replace every bearing and every seal.
Completely go through the tranny, and replace any gears or parts that look questionable, usually 2nd, 3rd, and 4th gears will show the most wear. Check to be sure the forks are within spec and not bent. Be sure to replace all the snap rings in the tranny!...or it could come back to bite you later, then you'll have to split the cases again to replace a $2 part. Check the shift drum for excessive wear...and check the shafts real good too.
What connecting rod do you have?...hopefully an OEM or Wossner.
Check your cylinder's intake bridges and exhaust ports real good for cracks.  

I'm sure other members can come up with more things to look for, but this will get you started.
 
here's a good link to read...it's LONG, but if you read it carefully, there's a LOT of hints and tips...
http://www.kxriders.com/forums/index.php/topic,8717.0.html

here's a couple good ones too look through...
http://www.kxriders.com/forums/index.php/topic,12120.0.html
http://www.kxriders.com/forums/index.php/topic,11657.0.html

[dirtridernh]

Thanks for the extra stuff about the tranny, I got a hot rod kit. OEM isn't available anymore. Is there a parts number list on this site for those bearings and washers?

[Foxx4Beaver]

no, but you can go on any OEM Kawie supplier, like Rocky Mountain ATV, BikeBandit, and get the part numbers.

just fill in what year/make/model yours is where it says "Search by machine"...
https://www.rockymountainatvmc.com/oem-parts/Kawasaki

[sandblaster]

I've got a basic kx500 parts list that we replace when doing a full rebuild.
It's on my other computer.
I'll see if I can remember to post it 
It has all the bearings, seals, washers, clips, yada yada

[Foxx4Beaver]

I've got a basic kx500 parts list that we replace when doing a full rebuild.
It's on my other computer.
I'll see if I can remember to post it  
It has all the bearings, seals, washers, clips, yada yada

should see if that list can be made a "sticky" in the KX500 Original or Engine Modifications forum ....seeing's how part# requests come up quite often here.

[sandblaster]

Not the greatest format but I'm working on it..

http://www.kxriders.com/forums/index.php/topic,16112.0.html

[dirtridernh]

This is wicked awesome, thanks for all the help!