1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN

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This was a interesting engine that came to us.
The base of the cylinder was machined .040", the squish on the head was .045", the timing was retarded, and the boost ports were hogged out.
Someone was looking for some more torque
But this customer want's HP and some more top end so we aim to please...

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Parts come to us like this..

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But they go back out more like this...

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Ordered the rod today.
We will wait for it to get here then polish it.
Then we will send it out for balancing, and rebuilding.

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The trans needed 3rd and 4th both input and output

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Balanced and ready for assembly.

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Ok.. prepping the cases for repair and case lapping..
Note the broken counter sprocket bolt tower

Here is what we are starting with

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Dirt things first, gotta remove all the bearings, seals, and bearing retainers..

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Shish Kebab!!!

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When lapping you can have your buddy hold the cases for you or.....

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Timesaver is the best stuff out there for lapping aluminum..

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Gotta get the Timesaver on the entire surface

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This is the typical trouble area for KX500's... Note where the dark grey is around the edges of the cases.
Then look at the yellow area.
The yellow area means that the cases have a gap there.

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So rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl... rub rub rub... swirl swirl swirl...

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Now they are dark grey all around which means they are ready for clean up, porting, and repair,,

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Look at that cute little hole that feeds the main bearings...

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That's better, enlarged and countersunk

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Now look at this oil transfer hole.... See how high it is from the floor of the case?
When you drain the oil, this will leave some behind...

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Problem solved

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There are other improvements made but I can't show you them all