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Author Topic: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN  (Read 26768 times)

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Offline sandblaster

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1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« on: December 13, 2015, 02:30:13 AM »
This was a interesting engine that came to us.
The base of the cylinder was machined .040", the squish on the head was .045", the timing was retarded, and the boost ports were hogged out.
Someone was looking for some more torque  :-o
But this customer want's HP and some more top end so we aim to please...  8-)



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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: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #1 on: December 13, 2015, 02:32:08 AM »
Parts come to us like this..



But they go back out more like this...





Ordered the rod Friday.
We will wait for it to get here then polish it.
Then we will send it out for balancing, and rebuilding.
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Offline DoldGuy

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #2 on: December 13, 2015, 02:13:16 PM »
Not to sound retarded, but didn't you mean advanced.... :roll:?
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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #3 on: December 13, 2015, 03:02:21 PM »
Yep, my error... again  :lol:
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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #4 on: January 14, 2016, 02:57:02 PM »
Balanced and ready for assembly.

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Offline alward25

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #5 on: January 14, 2016, 04:55:47 PM »
Looking good! :-D
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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #6 on: January 14, 2016, 05:43:51 PM »
I hope all those holes are correct  :-D
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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #7 on: February 15, 2016, 02:17:04 PM »
Case lapping, You guys know the drill  :roll:

Remove the junk



Hold the right case down..



Use this stuff (Thanks Motorrad)

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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #8 on: February 15, 2016, 02:18:22 PM »
This is the typical trouble area for KX500's... Note where the dark grey is around the edges of the cases.
Then look at the yellow area.
The yellow area means that the cases have a gap there.



rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl...



Now they are dark grey all around which means they are ready for clean up, porting, and repair,,
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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #9 on: February 16, 2016, 04:37:11 PM »


You know what's coming next  :lol:



This needs some attention as well..



All done..

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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #10 on: February 23, 2016, 01:38:19 PM »
So you take a ported to perfection and freshly plated cylinder with zero hours on it and what am I going to do?



Oh yeah... you know what's coming next

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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #11 on: February 24, 2016, 11:53:46 AM »




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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #12 on: February 25, 2016, 10:08:37 AM »
Counter sprocket bolt tower is done..
Before



After
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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #13 on: February 28, 2016, 11:52:57 AM »
All the transmission parts have been cleaned including the clips and all the new gears.
This one has many new gears including both 3rds and 4ths.



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Offline sandblaster

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Re: 1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN
« Reply #14 on: February 29, 2016, 02:59:23 AM »
Fresh out of the oven..



Fresh from the freezer.

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