1999 KX500 KAWASAKI ENGINE BUILD FOR KEVIN

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Fresh out of the oven..

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Fresh from the freezer.

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So your all ready for the big moment.... And what's gonna happen?
Watch the master at work

https://youtu.be/0JEPlaw_ZU8

Ok, so the crank is in and that's the easy part... Watch the master install the other case half..

https://youtu.be/Wp9g4RDLnow

Easy peasy

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Now it's time to install and torque the case bolts.

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Since we are waiting for the custom ported cylinder to get back from Milennium Tech Jason went ahead and rebuilt the clutch basket with a new basket

It turned out sweet...

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Not shown in the pics, all the bolts were dimpled to help hold them together...

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We managed to find a Vforce 2 red for this build so.... We need to modify the carb boot.
Stock..

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Ears are removed and sanded flat..

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Now whip out the VForce 3 reed and stuffer..... What???

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Yes... Put the VF3 in there with the stuffer..

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Now put some silicone of some type on the stuffer only...

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Now install the boot...

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Let it dry over night

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Reach in there and feel around with your finger... You will understand why I do this mod..

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After the goop has set up, carefully remove the boot and take a look at what you have..
Note the difference in the boot hole VS the stuffer hole..

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Clean away the excess goo without breaking the stuffer from the boot.. Then get a marker and mark the boot.

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Now remove the stuffer from the boot and see what you have..

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That yellow profile need to go away..
The first time I ever did one of these I used a small sanding drum on a Dremel.
My tools have improved somewhat since then...

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It's still a little rough but you get the idea..

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Now you can compare the VF3 stuffer and make sure that you didn't miss anything...
NEXT!!!!

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For those that know, enough said

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All Done!!!

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This engine will be a wild child with plenty of room for even more power

Shipped with no oil, although all the parts are fully lubed.
Do your heat cycles, then ride it easy.
By the end of your first tank start opening it up for brief periods.
By tank two let her rip.... Just don't hold it Wide Open for a mile straight until tank two is fully gone...
And by all means, check your plug color to be sure you aren't running lean...