2002 KX500 Kawasaki engine rebuild for Greg

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When you are rebuilding your KX500 engine this is not a good sign..

https://youtu.be/mzAoHiYxiqs

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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..

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Looks good...

The head came off and.... Looks good as well...

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Recorded the head squish

Piston and cylinder bore look decent..

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With a weight like that, this is definitely a trail rider

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Gonna need some new reed pedals..

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Measure and record the piston at TDC to the cylinder deck..

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Gonna need some welding and fab work

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Measure and record the ports.... All stock.... Ignore the reading on the wheel

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Here is where we found some issues..

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The piston is a bit buggered up...

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Unfortunately the piston wall is getting thin and it's got a dink in it.....

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Also the crank has some strange grinding marks on the side of it..

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It also has a lot of galling around the flywheel.... hmmmmm

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Then a closer inspection of the plating reveals some thin plating and some issues around the ports..

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Maintenance was not a issue on this bike.
Look how clean it is on the inside..

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The customer uses Royal Purple Synthetic 10/30

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I've been thinking about trying it for some time..

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Helicoil drain plug... We may have to fix this..

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Hmmm, I'm not certain what balance factor they were shooting for but these holes are a no go..

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It's a shame that this top end has very little time on it and for some reason it has some issues..

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Nice, clean, stock cylinder

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I'll fix that Got some roughing work to do..

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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

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When a customer send Jason his engine for a rebuild, this gives you an idea of what all he orders before work even begins

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All the lapping, case matching, and case port mods are done and the engine is ready for assembly.

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