kx500sf project

[jonny500]

it was tight but thats a good thing. i was carfull, i didn't want to un ballance the crank it cost alot

[Motorrad]

it was tight but thats a good thing. i was carfull, i didn't want to un ballance the crank it cost alot

Use the good old freezer/oven technique?     

[jonny500]

just had the bore and piston measured as follows piston = 3.374" / 85.70mm and bore = 3.386" / 86.00mm. this is out of spec by cylimer. is this ok to run or not 

[kaw rider]

the cylinder is good, but the piston is small or they measured the piston wrong.

[Motorrad]

the cylinder is good, but the piston is small or they measured the piston wrong.

Agreed... where on the piston did they measure?

You should have a .008" differance between the piston and bore total (if your running wiseco specs. (.004" clearance)

[jonny500]

i have just measured it with my digital vernier and it comes out 85.8mm that gives 0.2mm/0.008" . i am going to run it. the guy must have made a mistake. it was the bore i was struggling to measure anyway. thanks for your input kawrider/motorrad

[jonny500]

i little more progress. we may be hearing that sweet 500 2 stroke sound before the week is out

[junk man]

Jonny the Kawasaki SM i have is 1988  standard bore 86.020 -86.035mm
 max bore 86.10 mm and standard piston 85.910 -85.925mm max 85.80mm
and clearance is 0.105-0.125 mm

hope this helps  JM

[Motorrad]

i little more progress. we may be hearing that sweet 500 2 stroke sound before the week is out

CANT WAIT!..

[jonny500]

thanks jm. motorrad, neither can i but i may have been slightly optomistic in my last post. may get chance to put some hours in today. i am under going a training programe too, just so i can hold on to this thing when its done. time is short

[jonny500]

i was torquing the head bolt and 1 of the studs pulled out grrrrrr, got to helicoil it 

[junk man]

well it'll be good as new i hate when things like this happen

[Motorrad]

i was torquing the head bolt and 1 of the studs pulled out grrrrrr, got to helicoil it 

Ugg hate it when stuff like that happens..

Was building a toyota 22R motor about a year ago...  and was doing final torque on the head bolts (this is after a few heat cycles in the car.. so it was already in the car!!) ... and one... took the thread with her.. (wouldnt go to torque)...  UGGGGG...  makes you pull your hair out... (or what little some of us have left of it)

[jonny500]

ITS ALIVE helicoiled the barrel and got the motor to gether again. built it up so far. main jet 170, idle jet 60, needle m82r on 3rd clip, pilot air 1 turn out, putoline castor oil at 32:1. my experience of 500s is limited so please coment on the jet ect. it fired up first kick and ran fine on the stand. just got to sort the pipe a little, i am going to abandon the exhaust sleeve adaptor and weld it on. should be having the first ride by next weekend

[Dutch-K5 Fan]

Damm Jonny, looking good!!
You must have butterfly's in your stomic and eager to ride the beast

Feels great, isn't it


Dutchie