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Author Topic: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE  (Read 12671 times)

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Offline sandblaster

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KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« on: May 10, 2016, 04:09:07 PM »
We received a bottom end from Scot for a rebuild.
The bike was purchased, not running a while back for a real steal of a price..
When we got it, I looked it over.
The cases were good, the crank looked pretty good so I thought this will finally be an easy one...
WRONG!!!
But before I get into that, I already had a KX500 crank on hand and ready to go... Balanced and polished with a Wossner rod...



And, I had our basic parts list on order with our local Kawasaki dealer..





Further, the Cometic gaskets and a few other parts came in quick...

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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: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #1 on: May 10, 2016, 04:10:17 PM »
When I opened the engine I saw that it was the best packaging job I had ever seen.
We do a pretty good job but this was awesome..
Unfortunately my cel phone broke and I couldn't take any pics...

Next I washed up the engine, don't want any extra debris getting into the engine..

Then I started on disassembly..

The flywheel had some unexpected damage..



I have never seen one quite like that before..

Next I noticed that the clutch washer was really worn..



Something was definitely up on this engine..
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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: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #2 on: May 10, 2016, 04:11:35 PM »
Needless to say, we will be checking the ohm specs on this before it ever goes back into the engine...
There will also be a bit of clean up involved



Man, even the shift shaft spring is worn out



All but three gears are junk... Both shafts are also done for





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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: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #3 on: May 10, 2016, 04:13:39 PM »
Now you might be saying... Wait a minute, can't you get the gear dogs undercut?

Normally yes, however, the splines that the gears attach to the shafts on are worn out.
And the snap rings that hold the gears in their relative positions are completely wallered out....
Definitely something bad happened here..



Then we discovered the problem...
Here is another case out of my top secret stash..
See the steel insert where the output trans shaft goes?



This engine had no insert..



That means that the output shaft was just flopping around in there...
It's a wonder the engine did not grenade..



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Offline sandblaster

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #4 on: May 10, 2016, 04:14:58 PM »
The cases and clutch cover were warped pretty bad.
We had to spend some time on the granite surface plate before we could even lap..



In all fairness, someone had welded the clutch cover fairly extensively..



Once that was done Jason mixed up some Timesaver, 100 grit (Very fine) and started lapping the cases to insure a positive fit with no air leaks..



Timesaver is so amazing... I thank Motorrad every time I use this stuff..
Bolt one case to the table so it doesn't walk around on you and go to town

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Offline sandblaster

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #5 on: May 10, 2016, 04:15:57 PM »
Back and forth, side to side, swirl and swirly.. Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat..Repeat.. ect...





Jason even lapped the clutch cover

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #6 on: May 10, 2016, 04:16:45 PM »
Jason on the Vapor Blaster..



Then into the Ultrasonic cleaner



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Offline sandblaster

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #7 on: May 10, 2016, 04:17:24 PM »
The results are amazing..





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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #8 on: May 10, 2016, 04:18:20 PM »
New parts..



More new parts..



Waiting... waiting...

.

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #9 on: May 10, 2016, 04:19:09 PM »
Ready for bearings and seals..



Hot!!!

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #10 on: May 10, 2016, 04:20:02 PM »
Bearings and seals are in.... Just waiting for the replacement transmission....



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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #11 on: May 10, 2016, 04:46:52 PM »
Scot just sent me this... Anodized and ready for bearings..

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Offline Foxx4Beaver

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Re: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #12 on: May 11, 2016, 07:12:22 AM »
those look sweet!! 8-)

Quote from: sandblaster on May 10, 2016, 04:46:52 PM
Scot just sent me this... Anodized and ready for bearings..



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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: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #13 on: May 11, 2016, 10:21:09 AM »
Jason and I have been talking about Anodizing.. It's not hard to do relatively speaking.
I just don't want to deal with the chemicals.
But, we'll see...
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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: KX500 BOTTOM END REBUILD FOR SCOT By JT Engine Works & OEM-CYCLE
« Reply #14 on: May 11, 2016, 10:24:48 AM »
who did those for you?
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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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