2006 kx500af Done Building, Needs Tuning

[crooscroos]

My kx500af is complete it just needs a little tuning done. I used a 2003 kx500 motor with a 2006 kx250f frame. It vibrates like crazy so I am looking to put rubber washers on all of the engine mounts, along with Flexx handlebars and a steering stabilizer. The motor has a brand new Wiseco piston that has just been broke in. The bike is running a little rough so I may look at jetting options, any opinions out there? Also, I am struggling to keep the temperature down, I routed my radiators according to a diagram I found online but my bike is running around 235 degrees which seems a little high to me. I am losing a little coolant ever now and then as well. Any advice or questions are appreciated and encouraged!

Thanks, Cody

[sandblaster]

Hey Cody.
Nice bike.
What is the altitude you ride at now?
What is your current jetting?
Is that water temp or head temp?
What are you doing to reach that temp and what was the air temp?
What coolant are you running?
Did you burp the head and the left radiator?
When you installed the head gasket which side did you put the small holes on?
Post a pic of the rad hose configuration you used.
It looks like the back of your bike is sitting a little low?
Have you checked the sag?

[umberto]

I had a lot of luck with Best Dual Sport Bikes handle bar ends.  They killed all the vibration on my 2004 KX 250.

http://www.kxriders.com/forums/index.php/topic,14005.0.html

[alward25]

sounds like its time for an overhaul to include a crank balance,  Highway dirtbikes and Fasst Flex also have brass bar end inserts.

my only real words of advice, watch till the end

https://www.youtube.com/watch?v=qBR0oNp9A7c

[crooscroos]

Hey Cody.
Nice bike.
What is the altitude you ride at now?
What is your current jetting?
Is that water temp or head temp?
What are you doing to reach that temp and what was the air temp?
What coolant are you running?
Did you burp the head and the left radiator?
When you installed the head gasket which side did you put the small holes on?
Post a pic of the rad hose configuration you used.
It looks like the back of your bike is sitting a little low?
Have you checked the sag?

I'm planning on making it a sand bike so I'm riding at close to sea level.Main Jet 165-168

I'm running stock jetting at:
Pilot Jet 52
Needle STOCK
Clip Position 3RD
Air Screw 1.5 out

That temp reading came from the heat strip located just bellow the KPS on the cylinder. You can see in the 3rd picture.

I was riding in the sand when I reached that temp but I was not riding aggressively by any means. Air temp was 55 F.

I'm running a 50/50 mix of Napa coolant and water.

How do you burp the left radiator? I simply topped it off after 30 minutes of riding.

It was so long ago when I put the head gasket on, I don't remember where the little holes were. I thought it only fit correctly one way when I put it on. 

I copied Benny Lindberg's radiator hose setup but I can't seem to find his write up at the moment.

I thought the back was sitting a little low as well. I haven't checked the sag but I plan to in the near future!

[crooscroos]

From experience, which inserts do you guys feel are the most effective?

[sandblaster]

52 pilot?
That's pretty lean for the coast at 55F.
You might want to go to a 55 or even a 58 depending on what you find with the 55.
And run the 168 main and do some wide open throttle chops and check it again.
I'd put the 55 in it and run it for a while then check the plug.
That could be the biggest part of your heating.
Neither of my K5's liked the 52 for the coast at lower air temps.

Look at the top of your left radiator.
There may or may not be a plug in the top.
If there is, take the plug out and make sure there is no air trapped there.
If there is no plug, don't sweat it.

You can put the head gasket on reversed and not even know it.... (Speaking from experience)...
It needs to be on the correct way to make sure you get even cooling in the cylinder.

To help lower the temps a bit more, run some Royal Purple Purple Ice at the recommended dilution ratio.
It's good for several degrees of cooling but it is no substitution for a correctly jetted bike.

[crooscroos]

My left radiator is actually a modified right side radiator where the cap was sealed off. I'm actually looking for a better replacement for the left if you have any suggestions?

[crooscroos]

Here is a rough diagram of my radiator routing. Should I take the cylinder off and check that gasket?

[sandblaster]

I wouldn't remove the head just yet, (Ok I might...) But that's cause I'm nervous about such things 
Get your jetting right and then see where you are at.

[dave916]

""I'm running a 50/50 mix of Napa coolant and water.""

Try running distilled water  {no coolant} 
too much coolant could cause overheating {depending on type as is thicker and flow is slower}

Your crank seal {air leak} could be leaking if  your crank is running rough

[crooscroos]

After talking to the previous owner of the 500 I believe it has the stock jetting! Where should I go from the stock jetting? What bar inserts are your favorite Sandblaster?

[sandblaster]

52 might be what came on the bike from the builder but it's not stock Kawasaki jetting.
Again I think you better look at a 55 or a 58 pilot, 168 Main, needle at the 3rd clip position and about 1.5 turns out on the air screw.

Bar inserts? I don't need no stinking bar inserts...
I don't even ride with gloves... 

https://www.youtube.com/watch?v=hObZKApxAt4

No idea.... Never rode with any inserts...
Balancing your crank makes a world of difference.

[crooscroos]

Do you know anybody who can balance my crank well for a bargain price? I'm working on a college kid's budget

PS. Only a true bad@ss rides a K5 without gloves 

[sandblaster]

Contact GREENKAW24

http://www.kxriders.com/forums/index.php?action=profile;u=1767

Todd has done both of mine....