Can't get it started

[fredunderwood]

Ok, I've got fuel, I've got spark, I've got air, I've got compression, but can't get my kx500 to start.....any ideas are appreciated.   This is a new assembly, so I haven't had it started before.

[Foxx4Beaver]

what is your starting procedure?....this can make a difference.

[Foxx4Beaver]

I don't mean to insult your intelligence, but I've seen even the most seasoned mechanics do it before by accident and pull their hair out for hours and even days...just to find out they forgot a paper towel/rag in the motor or exhaust, that was used to keep debris out during assembly.
Just another possibility.

[fredunderwood]

Not at all insulted.   No rag

[Foxx4Beaver]

you say you have fuel and spark...is the plug wet?
try disconnecting your kill switch.

[fredunderwood]

Took the plug out, sparks, press kill button in and it doesn't.

[sandblaster]

Assuming that your bike is mechanically sound and correctly jetted here is what I do.
Turn on the pet cock valve.
Lean the bike over until a little fuel drips out the over flow.
Straighten the bike up.
Turn on the choke.
Slowly rotate the engine until it is just past TDC.
Quickly jump up and kick a full swing on the kicker with all my weight.
Usually takes 2-3 tries before it will fire.
Anything less then my best effort kicking it over and it won't start.

[Foxx4Beaver]

you had said in a previous thread right before X-mas that you had it running/idling, but as soon as you gave it throttle, it would die out, and then it would just kick back when you tried to start it again after that.

http://www.kxriders.com/forums/index.php/topic,12317.0.html

That "could" be a sheared flywheel key causing the kickbacks.

I just went through the same thing after installing a bigger brand new carb....I had to fatten up the pilot to get it to go above idle...once that was done it ran great, but fell flat on it's face in the upper revs....so I had to fatten up the main...now it has power all throughout....but, I still have a lot of fine tuning to do, and the weather is not ideal here for testing...15 degrees for high temps and we're expecting a ft of snow tomorrow and Friday, so I don't know when I'll get back to it.

I should also point out that mine was a COMPLETE rebuild....I'm actually embarrassed to say how much I spent this time.....and mine was a bitch to get started the 1st time, most likely from all the oil that was in the cylinder from assembly....it took 10-12 hard kicks.   

[fredunderwood]

I'm gonna pull the flywheel today....but, I have read in a climber manual, if spark is "weak" versus a fat blue spark, that could be the problem....so subjectively, yes there is spark, but fat and blue? Uh we'll?   I'm also going to check for connections versus the wiring diagram to see what I can find, but I have no answer to tell if my spark is weak versus fat?

[Foxx4Beaver]

Take a browse through this thread when you get time....very helpful, useful info.
A lot of it you may already be aware of, but still good reading.

http://www.kxriders.com/forums/index.php/topic,10928.0.html

Keep us informed.

[motopunk]

I'm gonna pull the flywheel today....but, I have read in a climber manual, if spark is "weak" versus a fat blue spark, that could be the problem....so subjectively, yes there is spark, but fat and blue? Uh we'll?   I'm also going to check for connections versus the wiring diagram to see what I can find, but I have no answer to tell if my spark is weak versus fat?

if you retard the timing a little bit, the engine will start easier.. 
the spark must look strong ... it does not real matter if blue or white colored ...  i had the phenomenom that with one sparkplug blue spark and tryed another and made a white strong spark. performance on running mashine was no difference..  both plugs were brand new ngk br8 ecm 

what is your actual jetting?? that could also bring some light at this point.

another reason could be to much compression, that the engine dont start. which head-gasket is installed the 0,5mm or the 0,25mm that was optional available from kawasaki??  a second base gasket would also help...

[fredunderwood]

Juuuuuuust a little update.    So, as I said earlier, I was going to pull the flywheel an test all connections.....right?   So I pull the stator cover.....can you guess whats coming?    The flywheel was spinning freely on the Crankshaft.......geeeze!   That's a problem, Right??

[Foxx4Beaver]

haha.... that'd do it...I had a feeling that's what it was.

[motopunk]

Juuuuuuust a little update.    So, as I said earlier, I was going to pull the flywheel an test all connections.....right?   So I pull the stator cover.....can you guess whats coming?    The flywheel was spinning freely on the Crankshaft.......geeeze!   That's a problem, Right??

fix it properly and give us some noise 

[fredunderwood]

What can I say......you guys totally Rock!!!!! And to think, I was just going to give up and take this to the shop and pay $400 to replace a $3.00 part!!!!!!!