kx500sf project

[Motorrad]

Yeap! Pull the pins and swap ends & reinsert. IMO the pins are cheap enough to just replace & I bought a new center valve & will fight with the old one later.

I had to buy another center valve also... as whomever tryed to do the pin flip on mine, while the motor was not in my custody... beat the living crap out of my flapper.... to the point of it not being usable IMO...

[jonny500]

hi don, the doordie pin flip (what i call it) all is described at 3.3 here http://www.hallbergs.net/kx500/
the pin flip went ok for me about the only thing that has lol

[kaw rider]

I flip a set of pin on a cylinder and they loosen up and jammed up the powervalves and it stuck the powervalves and it was a pain to get out. So i tack weld the pins now.

[jonny500]

motorrad, my ring gap is 14 thou. so thats good right?

[Motorrad]

motorrad, my ring gap is 14 thou. so thats good right?

Perfect..  Your golden....

I just ordered 4 sets of rings in hopes one set will measure what yours do...

[jonny500]

when i put my piston in the bore it feels very lose, is this a forged piston or a 500 thing. i have loads of experience building 2stroke motors but never used a forged piston or built a 500 (they just not very common over here)

[kaw rider]

I would measure the bore and piston to be sure what you have.

[Motorrad]

I always check the work of the plater bore etc,..
Not everyone has a bore gauge.

You can kind of fake it with those feeler gauges you have..

Not the best and most accurate way.. But better than closing your eyes and slapping it together...

[jonny500]

yeah i think you are all totally right. i just dont have the equipment to accuratly measure it here. i can take it some where to have it done, i think i will do that as it better to be safe. this thing has cost alot and i plan on keeping the motor for years to come, i will just keep puting it in newer frames as they come along.

[dave916]

hi don, the doordie pin flip (what i call it) all is described at 3.3 here http://www.hallbergs.net/kx500/
the pin flip went ok for me about the only thing that has lol

the pin that joins the two section of the centre kips is the same as the pins your flipping,
only ?1.73 each so no real need to flip pins when you can buy new
part no 92043
PIN,4X23.8 ?1.73 

[Motorrad]

yeah i think you are all totally right. i just dont have the equipment to accuratly measure it here. i can take it some where to have it done, i think i will do that as it better to be safe. this thing has cost alot and i plan on keeping the motor for years to come, i will just keep puting it in newer frames as they come along.

Its alot cheaper to do it right the first time... than do it twice...

[jonny500]

thanks dave, i have done it now so no need but usfull info. new bearings all round in the bottom end. assembled so far as you can see. just waiting for the new clutch plates to soak over night. should hopfully have the bottom end complete over the weekend

[dave916]

looks like that crank took a bit of balancing?  did u get it welded or not? chis did not weld mine but i am still thinking about welding (cold) it myself,
is that the head gasket 1mm in picture u are using?
U can get a genuine  0.4mm steel from Cornwall for under 12quid 

{when i sent my barrel with prox piston to langcourt   i sent all clearance etc from cylmer manual }

[jonny500]

the crank looks like swiss cheese lol, looks like they had to take alot out. that is a lancourts cylinder, i think they are the best in the U.K so i am sure it will be right but i am going to check it any way. crank not welded i dont think it needs it, time will tell. the gasket it a mitaka, no idea of the thickness i will use it for running in, then lift the head to check every thing and set the squish, how is yours going dave, is it together yet

[Motorrad]

thanks dave, i have done it now so no need but usfull info. new bearings all round in the bottom end. assembled so far as you can see. just waiting for the new clutch plates to soak over night. should hopfully have the bottom end complete over the weekend

Darn your ahead of me now!...


Looking good..

Crank give you any trouble going in the cases?