Building a 91 KX500 engine

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Crank half is done.

CRANK HALF.JPG (47.79 KiB) Viewed 7244 times

The company I had repair it had to grind it undersize then plate it, then grind it to the finish size...
Perfect!

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A little more progress today.
Minor clean up.... Got to get it clean enough for the plating tank.
So we still have some work to do.
Drilled out the drain hole.
Modified the main bearing oil hole and entry point.

BASIC CLEAN UP ENGINE CASE KX500.JPG (105.1 KiB) Viewed 7233 times

basic clean up.JPG (136.9 KiB) Viewed 7233 times

OIL DRAIN HOLE DRILLED OUT FOR TIG.JPG (40.03 KiB) Viewed 7233 times

oil hole mod kx500.JPG (41.07 KiB) Viewed 7233 times

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After I left the shop last night I asked Jason to finish cleaning up the case in prep for plating.
The instructions from the plating shop was that it had to be EXTREMELY clean or they wouldn't put it in their tank.
That makes perfect sense as those tanks are a mixture of chemicals that must be kept in a certain balance or your plating does not work right.
I think this qualifies as EXTREMELY clean

91 KX500 OEM-CYCLE.COM PREP FOR PLATING BEARING 101.JPG (77.99 KiB) Viewed 7231 times

91 KX500 OEM-CYCLE.COM PREP FOR PLATING BEARING 102.JPG (76.07 KiB) Viewed 7231 times

91 KX500 OEM-CYCLE.COM PREP FOR PLATING BEARING 103.JPG (87.61 KiB) Viewed 7231 times

91 KX500 OEM-CYCLE.COM PREP FOR PLATING BEARING 104.JPG (73.3 KiB) Viewed 7231 times

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Here is a pic of their main plating tank.

91 KX500 OEM-CYCLE.COM PREP FOR PLATING BEARING 105.JPG (161.44 KiB) Viewed 7231 times

So they have the case and the factory bearing for size reference.

91 KX500 OEM-CYCLE.COM PREP FOR PLATING BEARING 106.JPG (91.11 KiB) Viewed 7231 times

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When the case comes back it will go out for weld.
Then we will drill and tap the drain plug hole.
Then we will make all the case mods and lap the cases for a perfect fit.
After that they will go into the Vapor blaster one last time for a perfect clean up.
Followed by bearing and seal installation.

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Off to Pinsonnault Racing for the full treatment...

91 KX500 OEM-CYCLE.COM WOSSNER ROD KIT 101.JPG (32.31 KiB) Viewed 7222 times

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Everything has been ordered and sent off to different vendors.
Looking forward to seeing this one complete..

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Welcome to our case lapping shop.
Notice how when we first start the sedges are dark gray and the center is yellow?
That's because the outside edges are making contact but the inside of the cases are not.
Can you say Air Leak?
We knew you could!!!

91 KX500 OEM-CYCLE.COM CASE LAPPING 107.JPG (48.04 KiB) Viewed 7159 times

After 10 minutes on the lapping machine you can see that there is more dark grey...
But still there is that persistent yellow in the middle.

91 KX500 OEM-CYCLE.COM CASE LAPPING 108.JPG (80.09 KiB) Viewed 7159 times

After about 20-25 minutes total we are getting a nice consistent dark grey all the way around... Success!!

91 KX500 OEM-CYCLE.COM CASE LAPPING 109.JPG (106.69 KiB) Viewed 7159 times

Meet my lapping machine... His name is Jason

91 KX500 OEM-CYCLE.COM CASE LAPPING 110.JPG (146.36 KiB) Viewed 7159 times

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Enlarging and chamfering the main bearing oil passage for better lubrication..

91 KX500 OEM-CYCLE.COM CASE LAPPING 111.JPG (51.38 KiB) Viewed 7159 times

Now for some oil passage massaging at the porting table..

91 KX500 OEM-CYCLE.COM CASE LAPPING 112.JPG (103.7 KiB) Viewed 7159 times

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All new snap rings, bushings, and collars.
Clean too...

91 KX500 OEM-CYCLE.COM TRANSMISSION REBUILD 113.JPG (116.23 KiB) Viewed 7153 times

91 KX500 OEM-CYCLE.COM TRANSMISSION REBUILD 112.JPG (170.35 KiB) Viewed 7153 times

Before

91 KX500 OEM-CYCLE.COM TRANSMISSION REBUILD 114.JPG (264.6 KiB) Viewed 7153 times

After

91 KX500 OEM-CYCLE.COM TRANSMISSION REBUILD 115.JPG (203.06 KiB) Viewed 7153 times

Before

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After

91 KX500 OEM-CYCLE.COM TRANSMISSION REBUILD 117.JPG (210.56 KiB) Viewed 7153 times