1994 KX60 rebuild/refurbish

[Coop]

If this is the wrong forum, please feel free to move it. I have had a couple guys ask me to keep them informed of the rebuild so I thought I would just start a thread to document the work start to finish.

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.

[scotty dog]

I reckon bead blast it Coop, would look better than painting.

[ford832]

Looks like a fun project.Keep us updated on your progress.As for the finish question,the answer is obvious-bead it,then polish it 8)BTW,that is one big arse mutha farkin cam chain in the bottom pic.Must be a KXF60-shame on you

[Coop]

LOL I was wondering if anyone would make a four stroke joke when they saw the chain in that pic  . I decided I am going to blast it, but I don't think I will polish it. I am sure the 10 year old it's for is going to beat it pretty quick, 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 engine were stripped and I do not plan on putting them back in like that.

[Coop]

Some of the parts came today:

[socalcajun]

cool project  coop.  i prefer media blasting myself. always hated when people painted their engines. made them look like lawn mowers. LOL

[opfermanmotors]

I only painted my KTM 495 motor with spray paint, because I think that the spray paint is stronger than the motor cases!  Didn't bead blast it or anything because if I did I would be left with a pile of dust. 

[socalcajun]

I only painted my KTM 495 motor with spray paint, because I think that the spray paint is stronger than the motor cases!  Didn't bead blast it or anything because if I did I would be left with a pile of dust. 

 

[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!"  :-D

[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.

[G-MONEY]

Check the run out on that crank, I saw a nightmare you tube on a wiseco crank for a 2001 CR250. They make them in tiwan, could have been a bad one but scince then they make me nervous...

[Coop]

I'll make sure I do that, thanks! I have used them before but never checked them, but I will from now on.

[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.

[scotty dog]

Looks like its comin along nicely for ya Coop, the cases look really good in the pics..