kx500sf project

[DaveEngineering]

Looking good Jon, cant wait to see it finished.

[jbersano]

great project.... great description!

[jonny500]

the cr 500 pipe a got off ebay turned out to be a 250 pipe so the build has been held up

[jonny500]

removed head stay, i will sand blast to give a factory finish (another of torches ideas)

[jonny500]

after the ebay problem  i purchased a new dep pipe. i had a sleeve adaptor made to join the pipe to the exhaust port, i will have to see how this works/seals. the bottom mount is a kx 500 damper mount with the hole elongated and the rear is one i made, i will make a proper one with a rubber later. i had to put 2 dents in it 1 for the water pipe and 1 to clear the top of the engine. if this works the only mods for changing the pipe will be the 2 dents so a stock cr pipe can be fitted in about 20 mins use a hammer. here some pics

[cutting torch]

removed head stay, i will sand blast to give a factory finish (another of torches ideas)

What happened to your bleeder screw?

Also, if you spring for shipping, I'll send you some of the large glass bead that I used. Your headstay removal looks great, BTW.

torch

[jonny500]

thanks for the offer but i am ok for blasting, i have a friend. the bleed was like that when i got it, i will helcoil it befor the final build up

[kaw rider]

i would be careful with the bleed screw area when installing a helicoil

[jonny500]

i would be careful with the bleed screw area when installing a helicoil

why

[DaveEngineering]

i would be careful with the bleed screw area when installing a helicoil

why

no answer was the stern reply lol, wouldnt it be better just to run a tap through it?

[kaw rider]

there not alot of meat are the thread area. last thing is you dont what a coolant leak there.

[jonny500]

to be honest, the head is pretty beaten up i may use it as a practice for a de-comp and source a better one. but yeah i hear what you are saying kaw rider. i have bought some new casing from an 02 and a gear box from a 2000. i have sourced a recon barrel on an exchange basis, the clutch is new anyway. to be honest i will be using very little from the old engine, in fact you cant really call it the same engine lol

[jonny500]

dave engineering, i take it you mean a larger tap than the m6 (you cant put a thread in fresh air) and use a larger bolt. the next size would be m8 and as kaw rider says theres not a lot of meat. another option is to fill with weld and start a fresh with the m6, i will come up with somthing i am sure

[kwakman]

jon, I used to end all my rides with a wrecked flywheel woodruff key, and if yours moved it could have fired while the piston was still moving up, bending your rod. The cure? simple, cheap, and it never moved afterwards.get some valve grinding paste(being careful to keep it away from seals if crank in engine) and put some on taper using coarse paste first, then fine paste, and spin flywheel back and forth for about 5 minutes each type of paste which matches flywheel to crank taper.IT WILL NOT MOVE AGAIN.The present woodruff key is over 3 yrs old and no more dnf's as it were.Result.K.

[jonny500]

wakefield off road said they will supply a good crank half for ?60 and i also have another crank here as well. i have heard of that fix befor never tried it though. the flywheel and crank are pretty ruined the pics show it favourably. i wil do the grinding paste thing on the new to me/second hand parts to be sure, i dont want any more little problems lol