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Author Topic: 91 kx500 engine disassembly and inspection  (Read 21318 times)

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Offline dave916

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Re: 91 kx500 engine disassembly and inspection
« Reply #30 on: August 19, 2015, 05:32:00 AM »

I would be carefull drilling that oil way much bigger as there is very little meat on the outer sides
I Would usually use a dremel  to widen the area behind the main bearing  and  countersink the top




« Last Edit: August 19, 2015, 05:35:17 AM by dave916 »
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #31 on: August 19, 2015, 05:35:43 AM »
Your right, 6mm is the max we go.
We have been considering enlarging the outlet as your picture shows as well..
Thanks for sharing.
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #32 on: August 19, 2015, 01:40:25 PM »






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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #33 on: August 19, 2015, 01:41:41 PM »








Getting closer
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline dave916

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Re: 91 kx500 engine disassembly and inspection
« Reply #34 on: August 19, 2015, 09:35:38 PM »
Looking  good.
Is that a team green top end?   
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Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #35 on: August 20, 2015, 02:28:46 AM »
Quote from: dave916 on August 19, 2015, 09:35:38 PM
Is that a team green top end?   

It was slightly modified when we received it from the customer.
We did the Team Green mods and a couple of Motorrad mods.
Nothing scary  :-D
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline ecdeyzel

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Re: 91 kx500 engine disassembly and inspection
« Reply #36 on: August 20, 2015, 02:35:49 AM »
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2007 Suzuki DR650SE
1999 Kawasaki KX250 (Rebuild in Progress)

Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #37 on: August 20, 2015, 10:48:16 AM »
Done and ready to ship.
I hope the owner gives you all the love and RESPECT you deserve or, you'll break more then his heart  :-D



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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline ecdeyzel

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Re: 91 kx500 engine disassembly and inspection
« Reply #38 on: August 20, 2015, 06:53:44 PM »
Thats beautiful Sandblaster, well done! Thats going to be one happy customer.  :-)
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2007 Suzuki DR650SE
1999 Kawasaki KX250 (Rebuild in Progress)

Offline umberto

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Re: 91 kx500 engine disassembly and inspection
« Reply #39 on: August 21, 2015, 03:38:11 AM »
That's got to be like one of your kids leaving the house when they grow up.   :-D
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline sandblaster

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Re: 91 kx500 engine disassembly and inspection
« Reply #40 on: August 21, 2015, 04:42:15 AM »
Thanks guys.
I'm sure the owner will be very happy.
Now I have to get started on the next one  :-o
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Singletrack

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Re: 91 kx500 engine disassembly and inspection
« Reply #41 on: August 21, 2015, 06:20:07 AM »
The motor is going to a very good home, mine.
I can't wait for it to show up.
I will say thanks for all the hard work and time you put into it.
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Offline umberto

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Re: 91 kx500 engine disassembly and inspection
« Reply #42 on: August 21, 2015, 08:45:30 AM »
I'm a little jealous Singletrack, you're a lucky guy.  Sandblaster made that dude look better than a new motor.  I'm going to bet it will be fast as heck too.  We'll need a ride report of course.   8-)
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
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