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Author Topic: Project "I was only gonna clean the air filter!"  (Read 131259 times)

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Offline USMC 500

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Project "I was only gonna clean the air filter!"
« on: March 14, 2011, 05:25:35 PM »
OK so I'm starting another topic on the same topic that started over a year ago.  Let me catch everyone up.  Went to clean my air filter because the bike was running like crap and 3 hours later it was down to the frame!!

Here is the link to my original post for this project.....
http://www.kxriders.com/forums/index.php/topic,6905.0.html

So here are some pictures of whats happened in the last couple of days.  Some will be followed by questions for all of you kx500 masters.  

The Frame after powdercoat....silverado silver.


Other than the primary is there anything else that needs to come off before the cases are split?


The rod is supposed to slide side to side slightly, however this rod also rocks side to side slightly....bad rod or bearing?


Should there be this much oil build up were the kips assembly sits?


Here is the cylider.....place comments here....lolll


Bottom of the jug....comments here....lolll


And finally, the book says I should have 2.6 to 3.6 ohms of resistance on the primary side of the coil and I have .5 ohms.  My leads have .3 ohms of resistance by themselves.  Is this were the extra resistance is comming from?
« Last Edit: March 30, 2013, 06:26:52 AM by USMC 500 »
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I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"

Offline sandblaster

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Re: Project "I was only gonna clean the air filter!"
« Reply #1 on: March 14, 2011, 05:44:31 PM »
On your crank, how far does it rock back and forth at the wrist pin?
We have found the following after they have been rebuilt from Hot Rods and others.
.020" New
.060" or less: Still usable
.060" or Greater: at the end of it's service life.
We have seen them still going at .120" but............

Just my .02 cents, If I was going to split the cases, I'd just re-build it.
Then again I like to sleep at night  :|
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Motorrad

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Re: Project "I was only gonna clean the air filter!"
« Reply #2 on: March 14, 2011, 05:46:14 PM »
Lets see.. where to start.

Splitting cases...
I notice in one of your pics.. the flywheel is on the motor... You must remove flywheel.. as this side is the case that will come off (and leave trans gears in the other case).
(like this)


You must remove the gear that is on the crank itself.. as well as the one tward the rear on one of the trans shafts. (there are 2 snap rings on this shaft, one above gear (you can see) and one under it, once you pull it.. both need to be removed...  (take out the kick start assembly as well.. or it will just fall out. and you will have to deal with picking up the pieces)









ROD
Ill dig out the specs on it... But UP AND DOWN play is what you need to worry about mostly..
But if your there... its only like $60 to have it rebuilt (labor) then parts..
Need i remind you what a failed rod bearing looks like..


 JUG.
Hard to tell from pics.. but looks like it needs a plate job...

How are the intake bridges? cracked like they all do? exaust bridges cracked? hard to see somteimes... look close

Coil..
Digging out specs...
« Last Edit: March 14, 2011, 05:50:37 PM by Motorrad »
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Offline USMC 500

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Re: Project "I was only gonna clean the air filter!"
« Reply #3 on: March 14, 2011, 05:53:34 PM »
Remove Rotor.....gotcha, up and down play on the rod is not happening but its good insurance to just have it rebuilt anyway, and remove kick start assembly, and both gears, gotcha....thanks boss.....much gratitude to all those on this site.
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I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"

Motorrad

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Re: Project "I was only gonna clean the air filter!"
« Reply #4 on: March 14, 2011, 05:56:11 PM »
Quote from: USMC 500 on March 14, 2011, 05:53:34 PM
Remove Rotor.....gotcha, up and down play on the rod is not happening but its good insurance to just have it rebuilt anyway, and remove kick start assembly, and both gears, gotcha....thanks boss.....much gratitude to all those on this site.

I think you have your specs wrong on the coil (or you made a typo)

Coil specs
Primary (Lead to metal body of coil, then to signal wire)
0.26-0.36 Ohms

Secondary (lead to metal body of coil, then to plug wire)
2.6-3.6 K Ohms

This is at 68deg F

I would Bypass the (bullet plug) for testing... as they are Poor.. especially getting on in their age... (all the connectors on my bike have been replaced with marine grade spade lock
« Last Edit: March 14, 2011, 05:59:20 PM by Motorrad »
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Motorrad

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Re: Project "I was only gonna clean the air filter!"
« Reply #5 on: March 14, 2011, 06:01:28 PM »
Just noticed somthing else... did you take the Plastic guide out from inside the kick start spring??
 :? :?

Can be seen here
http://www.kxriders.com/forums/index.php/topic,8717.msg69060.html#msg69060
« Last Edit: March 14, 2011, 06:05:34 PM by Motorrad »
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Offline USMC 500

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Re: Project "I was only gonna clean the air filter!"
« Reply #6 on: March 14, 2011, 06:09:26 PM »
Yeah I took out the plastic piece already....its sitting in the box with the clutch and everything else.  Good eye boss.  You're also right about the typo.  I did mean .26-.36 on the primary which I'm getting .5 ohms.  I'm also showing 2.9 ohms on the secondary side.  I'm using an Ideal meter cause my Fluke is at work.  I'll try the same readings with my Fluke tomorrow.  If I do have cracks on the intake and exhaust of the jug can they be fixed or would I need a replacment?  I'm gonna send the jug to Kaw Rider for service.
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I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"

Offline USMC 500

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Re: Project "I was only gonna clean the air filter!"
« Reply #7 on: March 14, 2011, 06:24:41 PM »
 :-o....crap, found a crack...is this bad?!


« Last Edit: March 30, 2013, 06:27:52 AM by USMC 500 »
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I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"

Motorrad

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Re: Project "I was only gonna clean the air filter!"
« Reply #8 on: March 14, 2011, 06:33:23 PM »
Nope...  Plater can weld em up.. good as new.. :mrgreen:

They did mine...


Wow.. those ports dont have any chamfer to em at all...
« Last Edit: February 26, 2013, 04:20:48 PM by Motorrad »
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Offline USMC 500

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Re: Project "I was only gonna clean the air filter!"
« Reply #9 on: March 14, 2011, 06:40:20 PM »
Do you recommend any porting or anything?    Thanks for all your help Motorrad.....I'm gonna have to make my way over to ya after this thing is built to do some riding....or maybe you should meet me in Mojave....Its about 20 min away from me.   :-D
« Last Edit: February 26, 2013, 04:21:04 PM by Motorrad »
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I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"

Motorrad

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Re: Project "I was only gonna clean the air filter!"
« Reply #10 on: March 14, 2011, 07:16:40 PM »
Quote from: USMC 500 on March 14, 2011, 06:40:20 PM
Do you recommend any porting or anything?  Or should I just have Kaw Rider fix, clean, and presto?  Thanks for all your help Motorrad.....I'm gonna have to make my way over to ya after this thing is built to do some riding....or maybe you should meet me in Mojave....Its about 20 min away from me.   :-D

Not sure if you have stumbled across this yet on the site..

http://www.hallbergs.net/kx500/

Id take the (slag) out of the boost ports.   rest of it.. is pretty darn good... for a desert racer,
(I clean all the casting flaws out of mine... and polish the exhaust).  But if your not handy with port work... you can do more damage than good...

I dont agree with the above articles sharpening of the dividers...
You learn some nifty things in fluid engineering class at UCSD...
« Last Edit: March 14, 2011, 07:25:30 PM by Motorrad »
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Offline USMC 500

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Re: Project "I was only gonna clean the air filter!"
« Reply #11 on: March 15, 2011, 12:03:03 PM »
Checked my stator windings and this is what I found....

Specs-153-230 Ohms: Black/White to Black/Yellow
          7.9-11.9 Ohms: White/Red to Black/Yellow


I have- 309 ohms Black/White to Black Yellow
           10 ohms White/Red to Black/Yellow

Is my stator starting to take a dump :|??
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I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"

Offline kaw rider

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Re: Project "I was only gonna clean the air filter!"
« Reply #12 on: March 15, 2011, 02:27:32 PM »
yes, i can fix the stator.
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Offline USMC 500

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Re: Project "I was only gonna clean the air filter!"
« Reply #13 on: March 15, 2011, 02:34:06 PM »
 :lol: :lol: Hold on there "mechanical Yoda, wise KX500 jedi master"!!  Whats wrong with my stator anyways?  Dont worry Kaw rider....as soon as some funds I'm expecting make it here you are getting my top end for a KIPS bolt, porting, re-plate, windowed Wisco piston, etc.....  We can work out the $$$ details as soon as I can send you the parts.  Does the stator high resistance contribute to the fact that my K5 was running like a turtles ass? :-D
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I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"

Offline USMC 500

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Re: Project "I was only gonna clean the air filter!"
« Reply #14 on: March 18, 2011, 05:39:14 AM »
Just sold an old front end off an old road race bike I had!!  A certified check for $450 is in the mail and on its way to me!!  More $$$ to feed the hungry project!! :-D

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I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"
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