1994 KX60 rebuild/refurbish

[Coop]

I bought a 1994 KX60 for my nephew recently. I got it really cheap and it came with a new cylinder. The guy said it just needed a piston/rings/gasket kit, but I suspected bottom end issues because these 60's are known to for that. Upon tearing into the engine I found a bad crank; the lower rod bearing race broke and that is what fragged the top end. I hope to start ordering parts this week. The frame and swing arm are getting repainted OEM colors. This is not a restore, just a refurbish so my nephew has a good looking, clean running bike to ride.

I am looking for opinions on engine finish. Should I paint it, or sand/bead blast it?

At the guys house:


About an hour after we got home:




I spent about an hour the other day and finished tearing the engine down:


Bad parts so far, well everything but the oil glass I broke, lol. I was pushing it out so the cases were bare for finish and I managed to hamfist it and crack the glass haha.

[Coop]

Yesterday I ordered the Wiseco complete crank kit with bottom end gaskets and seals, complete piston kit with top-end gaskets, a new shift lever to replace the mangled one, the parts to rebuild the water pump, and found a bolt kit on eBay. More than half the bolts on this bike were stripped and I do not plan on putting them back in like that.

[Coop]

Some of the parts came today:

[Coop]

So this project might go into hurry up mode and the cosmetic stuff might wait until winter. Once my nephew heard I started getting parts in, he said "Just put it together Uncle Mike, I want to ride!" 

[BDI]

I would do the cosmetic stuff. You will not have another opp to paint the frame. As far as the engine goes glass bead blast it. if you use sand it will be dull and gray. Glass bead will give it that bright silver factory look but you have to be double sure that you get it all out of the engine parts before you put it together. Make sure you blow out all of the bolt hole very well and put on some safety glasses. A little bike like this will bring more little kids happiness then just your Nephew. If you do a good job on it now then when your nephew out grows it and your buddies kid is learning on it the bike will still look good. Not to mention resale value will be higher but a kx60 is one of those bikes you never get rid of in my opinion. O ya and get the kid in on the project even if all he does is watch his uncle mike, chances are he will have as much fun as ridding it.

[Coop]

Well since the bolt kit is going to take longer than expected I decided to do some painting. I got the swingarm cleaned, sanded, and painted today. Yes it's just rattle can, yes I know it will scratch and chip easily, no I don't care,  . It's going to a 10 year old who is going to beat it I'm sure. I just want it to look nice when he first "officially" gets it.

[Coop]

I decided since funds are limited I would just apply a healthy dose of elbow grease and clean the cases instead of getting them bead blasted. A wire brush, some Simple Green and then Purple Power when I ran out of SG. They are not perfect, but they look much nicer.



I also painted the ignition and clutch side covers. The clutch side came out like crap, must have missed some oil. So I stripped it down and will re-spray it later or tomorrow.

[hughes]

looking good. I love watching these rebuild projects.

[Coop]

Starting to look like an engine:

[ThrottleJunky]

I have a pro circuit pipe and silencer for tha bike.    I'll send it if you need it.   Get that boy riding! 

Let us know how that Ebay bolt kit turns out. Quality or not!

[Friar-Tuck]

  Looking Good Coop!
Not only do you get to put together another bike, You get to get a kid out in the dirt!
  Thank you ThrottleJunkey for making the offer to Coop.  That's what makes this place the best little site on the web.
   Tuck\o/ 

[Coop]

How much would you want for that pipe ThrottleJunkey? This one is almost crushed right before the silencer, I am worried how that will affect performance.

The bolt kit is very nice! Definitely worth the $20. It was much nicer assembling the cases instead of the stripped phillips screws. The kit came with the case bolts, ignition cover bolts, clutch cover bolts, water pump bolts, and reed bolts.

Here's a crappy cell phone picture of the finished engine. The cylinder and head are way brighter than the cases, but it's ready to run. I called Nick today and told him his engine was done and he said "YES!". I have the frame sanded and will paint it tomorrow (just rattle can, money is tight) and then I get to start putting it all back together.

[ThrottleJunky]

Coop, The pipe and silencer aren't for sale.   PM me your shipping address.

[Coop]

Wow thank you! Really. Nick is so excited about riding this bike. It's great. He gos to church camp next week but tried to cancel because he knows his bike will be done  .

[Coop]

Frame is painted. It's lighter than I wanted (almost looks like shiny primer) but I couldn't find the shade I wanted in a rattle can. Once the new steering stem bearings come in I will start putting it back together.