I am tearing down the top end on my 2001 kx 500 for the first time. I have owned the bike for 2 years. I know that I should be doing this more often anyway, but the bike was running so great I didn't want to screw it up.
Anyway my bike has enough broken parts and the cold starting was getting so bad that I knew it was about time. I tore the bike apart yesterday and found a few things that need to be fixed: aftermarket reed valves cracked, broken support on radiator, etc. I new from the previous owner that the cylinder had been sleaved so I expected that, but I didn't expect the amount of metal removal that was done on the intake ports.
I found a couple of small cracks in the "normal" locations on the intake ports, but they don't appear to be cracked all the way through. My problem is that I really can't afford to put more money into this bike so I wanted opinions on the pictures I took and what you think should/can be done.
Cylinder Walls:
Intake Ports:
Piston:
Also, I am having serious problems removing the allen bolt that holds the KIPS in place. I am using so much force that I figure I am going to either break the allen wrench or strip the bolt. Anyone have any advice?
Their is also an issue with the amount of crap in the exhaust ports. Is this normal?
I can take more pictures of different areas, and of more detail if needed. I just want to make sure I get this back running and it doesn't self destruct on me in a month.