KX 500 clutch removal

[jbehunin]

Well, I got the nut off....finally!
I had to cut it off, but thankfully it came off rather easy once I cut through it.
 Got the complete bottom end all torn down and almost all the bearings out.

As I was using my case splitter to push out the crank, the main crank bearing stuck to the crank. Is there a special way to get this to come off?

Plus I am thinking of having the cylinder replated. What kind of piston should I use? I heard that stock kawasaki pistons are good, but are there other brands that will work with a freshly replated cylinder?

Also, as I was cleaning it off, the solvent I was using took off the paint of the engine. I guess the previous owner painted the motor with gray paint. Is there a special engine paint out there, or can I use engine paint to repaint it with?

[DoldGuy]

As I was using my case splitter to push out the crank, the main crank bearing stuck to the crank. Is there a special way to get this to come off?

That is a good sign! 

[kaw rider]

As I was using my case splitter to push out the crank, the main crank bearing stuck to the crank. Is there a special way to get this to come off?

That is a good sign! 

   are you sure doug.

[sandblaster]

It may or may not be a bad thing.
If it came out really easy then the case could be out of round and should be repaired or replaced.
If it came out hard then it is probably ok (Probably).
You will need to carefully mic it to be certain.
To get the bearing off the shaft you can use a bearing splitter like this:
http://cgi.ebay.com/LARGE-BEARING-SEPERATOR-PULLER-REMOVAL-SPLITTER-TOOL-/290526777943?pt=LH_DefaultDomain_0&hash=item43a4bed257
You need to buy the correct size, but a lot of these fit a wide range of bearings.

[DoldGuy]

As I was using my case splitter to push out the crank, the main crank bearing stuck to the crank. Is there a special way to get this to come off?

That is a good sign! 

   are you sure doug.

Shows signs that the crank journals are most likely good if the bearings stay with the crank instead of the cases. I have been told that on a good set of cases & crank, the bearings will stay with the crank. With that said, it does not necessarily mean either measures in specs but...............
DoldGuy

[sandblaster]

True, an argument can be made either way.
I have seen it true in both cases.
So, the moral of the story is, "measure it and see if it is in tolerance".

[jbehunin]

I have already bought all new seals, bearings, gaskets...etc to do the complete bottom end.
I wanted to replace everything.

But now I have a big problem!!!

Whoever put this bike together before, really F'ed it all up!!

In one of my earlier posts, I made mention that the clutch nut was on way tight, well, this guy put in so much red locktite on everything, nearly all the bolts in the cases have either stripped or sheered off.
One even broke one of the case halves!!!

Now I need to get new cases... Anyone have any ideas?

[meangreen]

Are you sure you want to buy new cases?  A visit with a reputable local machinist may give you another take on the problem.

Cases are expensive, labor should be much less.

Just my $.02

[kaw rider]

[quotethis guy put in so much red locktite on everything, nearly all the bolts in the cases have either stripped or sheered off.[/quote]

That sucks

[jbehunin]

good news!!!

I have a buddy who owns a cycle salvage shop. I gave him a call and he has the cases to a KX 500. I went to his house this afternoon and picked them up!!

So now I have new cases and I am happy!!!

But I still need info on where to go for cylinder replating?

And also what kind of piston can I use in a freshly replated cylinder?
also, what is a windowed piston and what are the advantages of them?
Where can I get a windowed piston?

Thanks!!!

[greencannon]

sounds like you made out big time on the cases...make sure they are in good order. Mic em like others have stated already and look close for cracks. Whoever you choose for plating, make sure you send them your piston for matching.  I would also have agood machinist look at you other cases. Would be nice to have a spare set 

[kxpegger]

good news!!!

I have a buddy who owns a cycle salvage shop. I gave him a call and he has the cases to a KX 500. I went to his house this afternoon and picked them up!!

So now I have new cases and I am happy!!!

But I still need info on where to go for cylinder replating?

And also what kind of piston can I use in a freshly replated cylinder?
also, what is a windowed piston and what are the advantages of them?
Where can I get a windowed piston?

Thanks!!!

http://mt-llc.com/

http://www.powersealusa.com/