2002 KX500 Kawasaki engine rebuild for Greg
- Sandblaster
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2002 KX500 Kawasaki engine rebuild for Greg
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
On this build we were hoping to save the crank and the top end and simply replace all the bearings, seals, washers, snap rings, bushings, ect.
This is what we received..
Looks good...
The head came off and.... Looks good as well...
Recorded the head squish
Piston and cylinder bore look decent..
This is what we received..
Looks good...
The head came off and.... Looks good as well...
Recorded the head squish
Piston and cylinder bore look decent..
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
With a weight like that, this is definitely a trail rider
Gonna need some new reed pedals..
Measure and record the piston at TDC to the cylinder deck..
Gonna need some new reed pedals..
Measure and record the piston at TDC to the cylinder deck..
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
Gonna need some welding and fab work
Measure and record the ports.... All stock.... Ignore the reading on the wheel
Here is where we found some issues..
The piston is a bit buggered up...
Measure and record the ports.... All stock.... Ignore the reading on the wheel
Here is where we found some issues..
The piston is a bit buggered up...
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
Unfortunately the piston wall is getting thin and it's got a dink in it.....
Also the crank has some strange grinding marks on the side of it..
It also has a lot of galling around the flywheel.... hmmmmm
Also the crank has some strange grinding marks on the side of it..
It also has a lot of galling around the flywheel.... hmmmmm
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
Then a closer inspection of the plating reveals some thin plating and some issues around the ports..
Maintenance was not a issue on this bike.
Look how clean it is on the inside..
The customer uses Royal Purple Synthetic 10/30
I've been thinking about trying it for some time..
Maintenance was not a issue on this bike.
Look how clean it is on the inside..
The customer uses Royal Purple Synthetic 10/30
I've been thinking about trying it for some time..
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
Helicoil drain plug... We may have to fix this..
Hmmm, I'm not certain what balance factor they were shooting for but these holes are a no go..
It's a shame that this top end has very little time on it and for some reason it has some issues..
Hmmm, I'm not certain what balance factor they were shooting for but these holes are a no go..
It's a shame that this top end has very little time on it and for some reason it has some issues..
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
Nice, clean, stock cylinder
I'll fix that Got some roughing work to do..
I finished the porting at about 12:30 this afternoon and got it shipped to Millennium Tech for plating... Oh yeah!
No, these pics are of the roughing work, not the finished cylinder
I'll fix that Got some roughing work to do..
I finished the porting at about 12:30 this afternoon and got it shipped to Millennium Tech for plating... Oh yeah!
No, these pics are of the roughing work, not the finished cylinder
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
When a customer send Jason his engine for a rebuild, this gives you an idea of what all he orders before work even begins
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2002 KX500 Kawasaki engine rebuild for Greg
All the lapping, case matching, and case port mods are done and the engine is ready for assembly.
If bikes are for kids I'll never grow up.
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