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Author Topic: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE  (Read 17438 times)

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Offline sandblaster

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2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« on: March 12, 2016, 07:05:30 AM »
Ok... Disassembling another KX500...
When you see this.... It's not a good thing  :|

https://youtu.be/mzAoHiYxiqs
« Last Edit: March 18, 2016, 04:45:35 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 Foxx4Beaver

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2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #1 on: March 12, 2016, 08:37:03 AM »
did I see the bearing come with it?...then hear it drop back into journal?...looked effortless.
« Last Edit: March 18, 2016, 04:45:55 PM by sandblaster »
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Offline sandblaster

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2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #2 on: March 12, 2016, 12:04:47 PM »
No, the bearing stayed in the case.. So that's all good :-)
« Last Edit: March 18, 2016, 04:46:08 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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2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #3 on: March 14, 2016, 08:05:41 AM »
On this build we were hoping to save the crank and the top end and simply replace all the bearings, seals, washers, snap rings, bushings, ect.
This is what we received..



Looks good...

The head came off and.... Looks good as well...



Recorded the head squish

Piston and cylinder bore look decent..

« Last Edit: March 18, 2016, 04:46:20 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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2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #4 on: March 14, 2016, 08:07:21 AM »
With a weight like that, this is definitely a trail rider



Gonna need some new reed pedals..



Measure and record the piston at TDC to the cylinder deck..

« Last Edit: March 18, 2016, 04:46:32 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: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #5 on: March 14, 2016, 08:08:15 AM »
Gonna need some welding and fab work  :-o



Measure and record the ports.... All stock.... Ignore the reading on the wheel



Here is where we found some issues..

« Last Edit: March 18, 2016, 04:51:51 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: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #6 on: March 14, 2016, 08:09:13 AM »
Unfortunately the piston wall is getting thin and it's got a dink in it.....



Also the crank has some strange grinding marks on the side of it..



It also has a lot of galling around the flywheel.... hmmmmm

« Last Edit: March 18, 2016, 04:51:33 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: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #7 on: March 14, 2016, 08:10:08 AM »
Then a closer inspection of the plating reveals some thin plating and some issues around the ports..



Maintenance was not a issue on this bike.
Look how clean it is on the inside..



The customer uses Royal Purple Synthetic 10/30



I've been thinking about trying it for some time..
« Last Edit: March 18, 2016, 04:51:16 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: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #8 on: March 14, 2016, 08:11:00 AM »
Helicoil drain plug... We may have to fix this..



Hmmm, I'm not certain what balance factor they were shooting for but these holes are a no go..



It's a shame that this top end has very little time on it and for some reason it has some issues..

« Last Edit: March 18, 2016, 04:51:00 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: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #9 on: March 14, 2016, 08:12:16 AM »
Nice, clean, stock cylinder



I'll fix that  :-o Got some roughing work to do..







I finished the porting at about 12:30 this afternoon and got it shipped to Millennium Tech for plating... Oh yeah! :D
No, these pics are of the roughing work, not the finished cylinder  :wink:
« Last Edit: March 18, 2016, 04:50:35 PM by sandblaster »
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Offline Foxx4Beaver

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Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #10 on: March 14, 2016, 08:38:37 AM »
Quote from: sandblaster on March 14, 2016, 08:10:08 AM
The customer uses Royal Purple Synthetic 10/30

I've been thinking about trying it for some time..

wasn't Motorrad using that at one time?....or at least an RP product in the tranny.
« Last Edit: March 18, 2016, 04:50:17 PM by sandblaster »
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Offline sandblaster

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Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #11 on: March 14, 2016, 10:25:36 AM »
He has used Royal Purple Purple Ice in the Rad...
I don't think he ever ran it in the trans.
Although he was looking into it at one time.
« Last Edit: March 18, 2016, 04:50:03 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 Foxx4Beaver

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Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #12 on: March 14, 2016, 10:31:16 AM »
Quote from: sandblaster on March 14, 2016, 10:25:36 AM
He has used Royal Purple Purple Ice in the Rad...
I don't think he ever ran it in the trans.
Although he was looking into it at one time.

he did...bout 1/2 way down...
http://www.kxriders.com/forums/index.php/topic,8310.0.html

couple more...
http://www.kxriders.com/forums/index.php/topic,7711.0.html
http://www.kxriders.com/forums/index.php/topic,5041.15.html
« Last Edit: March 18, 2016, 04:49:47 PM by sandblaster »
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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

Offline sandblaster

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Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #13 on: March 14, 2016, 11:38:53 AM »
Wow!
That first post was a bit before my time here.
Those were the Stewart days  :-o
« Last Edit: March 18, 2016, 04:49:34 PM by sandblaster »
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Offline sandblaster

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Re: 2002 KX500 KAWASAKI ENGINE BUILD FOR MOHAVE
« Reply #14 on: March 14, 2016, 11:39:55 AM »
Found out today that the shift forks were out of spec so we are replacing them as well  :|
« Last Edit: March 18, 2016, 04:49:21 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.
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