KX500 Cylinder removal

[bigtwin100]

I need to replace a base gasket on my 91 KX500. Top end is pretty fresh from the PO ( compression very good and piston/cylinder look almost new thru the exhaust port) and want to pull the cylinder with the head still on. Do I have to completely disassemble the KIPS or can I take the cylinder off with most of it intact?

[Magnus]

The kips can stay in there, you actually need to take the cylinder off to get them out. Just remove the cover over the actuator arm and that should be it..

I don't think it is possible to take the cylinder off without removing the head though, at least it would very tight under the frame...

[Polar-Bus]

I need to replace a base gasket on my 91 KX500. Top end is pretty fresh from the PO ( compression very good and piston/cylinder look almost new thru the exhaust port) and want to pull the cylinder with the head still on. Do I have to completely disassemble the KIPS or can I take the cylinder off with most of it intact?

Head has to come off first. There won't be enough room to slide the head/cylinder assembly off the piston assembly before hitting the frame.

[bigtwin100]

I read on here it can be done without the head coming off but no biggie if I have to. I have a very small oil leak at the front base on the throttle side. Pretty small but it's bothering me. It seems to go away when the engine get's warm. The plug is nice and tan and it runs very well so I don't think it's an air leak

[Polar-Bus]

I read on here it can be done without the head coming off but no biggie if I have to. I have a very small oil leak at the front base on the throttle side. Pretty small but it's bothering me. It seems to go away when the engine get's warm. The plug is nice and tan and it runs very well so I don't think it's an air leak

You shouldnt have "oil" leaking out of the base gasket, if anything you could be leaking some antifreeze. I could be wrong about the head having to come off first, but i'm almost positive the head hits the frame.

[bigtwin100]

I read on here it can be done without the head coming off but no biggie if I have to. I have a very small oil leak at the front base on the throttle side. Pretty small but it's bothering me. It seems to go away when the engine get's warm. The plug is nice and tan and it runs very well so I don't think it's an air leak

You shouldnt have "oil" leaking out of the base gasket, if anything you could be leaking some antifreeze. I could be wrong about the head having to come off first, but i'm almost positive the head hits the frame.

Ok this is interesting, can we talk a little more about this? I run the bike and can actually see oil coming out of the base gasket right in front on the throttle side of the bike. Someone said it could be a KIPS seal but I don't understand how the oil would come out there if it was a KIPS seal. It's not the pipe exhaust port as that is sealed up nice. It wasn't when I got it so maybe possibly it's residual oil that is boiling up that is still in the crevace there? It seems to have slowed.

[Polar-Bus]

Can you snap some pics and post ? I'm confused.....

[bigtwin100]

I'll try but sorry for my confusing post. Basically I had oil coming from (Where it seems to be coming from) the base gasket in the front, throttle side of the cylinder. Would there not be oil there but coolant instead?

[bigtwin100]

Would oil leak out of the base gasket?

[fraz83]

I have taken mine off without removing the head with no problems.. it would be a little easier because it is pretty tight.. but it can be done

[Polar-Bus]

I have taken mine off without removing the head with no problems.. it would be a little easier because it is pretty tight.. but it can be done

Getting things off is easy. Re-assembling things is always much more frustrating. I would rather be wrestling just a KX500 cylinder over the piston rings, than a cylinder with a head attatched that keeps slightly hitting the frame...