KX500 engine rebuild

[Mike D]

That is hands down the sexiest motor ive ever seen...

Wait till he posts the pics of it in the bike, probably the nicest 500 I've ever seen.

[Marco810]

Small update.

Sealed up a potential leak area, not sure why kawi machined through the cases to insert the bearing housing. Another great tip from kxriders, I take no credit for most of the mods ill be doing to this engine

[cnrcpla]

JB weld! I love that stuff  Works better than duct tape 

[Marco810]

Not much you can't fix with a rubber Mallet, Duct tape, and JB weld

[Marco810]

Here's one way to remove bearings (emphasizing on the previous post )

[Recovered]

put them in an oven with the bearings facing down at 400 degrees.

stand within an ear shot of the oven.  When you hear a "clank", the bearing is out.

Ask Charles.

[TotalNZ]

put them in an oven with the bearings facing down at 400 degrees.

stand within an ear shot of the oven.  When you hear a "clank", the bearing is out.

Ask Charles.

thats how i do mine, works every time no need for a hammer.

[Marco810]

GF wouldnt like that too much, but ill keep that in mind for next time. However that was a quick and easy method, few taps with a mallet, and im ready for new bearings

[Marco810]

This should be fun to play around with..



Crankshaft and 01 250 ignition is on its way, thinking about getting a hpi programmable cdi down the road. No idea on the eta on my jug, may call Eric if i find time this week

[Marco810]

Stuffing the crank pin. Thought about welding something on there but dont want to throw it out of balance too much

Eric is just "finishing up the head milling", should see my cylinder soon . Havent even ordered my piston yet... or carb... or..

[Marco810]

01 kx250 ignition..

[Marco810]

shinny new bearings. exept the shift drum bearings, dont see much point in replacing those

[Marco810]

Bottem end together. stator plate is going to need some work

[cnrcpla]

I have never split cases before, but when you do that, do you just line up the gear configuration with the bearings and all that stuff and put it together? Sorry if that's a stupid question, but I have done everything on a bike except splitting cases and rear suspension work.

[Marco810]

Ive only ever split Kawasaki cases so this may not apply to all, but i install install the shiftdrum, forks, gears, and crank, all on one case, then slide the other case on. the first case hold everything inline, so its a fairly easy process, only thing is you got to work quick when using a frozen crank and cases fresh out of the oven

also a case splitter is a must, never hit the crank with anything, just putting it out there