KX540 Big BoreDiscussion

Dirt Bike Technical discussion. This is for a little more in depth discussions :-)
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MrDuhfactor
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KX540 Big BoreDiscussion

Post by MrDuhfactor » Wed Mar 07, 2018 2:44 am

Have any of you built or have experience with a 540 BB motor? I'm curious your thoughts on reliability, performance, worthiness, and problems. Thoughts?
Never argue with ignorant people, they will just bring you down to their level and beat you with their overwhelming experience.

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Sandblaster
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Re: KX540 Big BoreDiscussion

Post by Sandblaster » Wed Mar 07, 2018 6:34 am

I'll get back to this question in the morning...
There is a lot to consider...
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: KX540 Big BoreDiscussion

Post by Sandblaster » Thu Mar 08, 2018 2:32 am

I've done 511cc, 523cc, 547cc, and 559cc.
All through bore with no stroking.

The first question you need to ask yourself is why am I doing this?
In other words, what kind of riding to you expect to do with the bike?

There are a lot of things to consider.
But the one thing that should not be a question is, build the bottom end like its going to be used and abused... because it will be.
Don't skimp on anything.
If your gear dogs are worn, get the re-cut or find some good gears.
Measure and compare everything to you Service Manual.
Replace every bearing, seal, washer, spring, bushing, ect...
Rebuild that crank unless it is in new spec.
If you rebuild it, balance it.
And oh yeah, use a Wossner rod... they are bullet proof.

Every engine I build has the best bottom end I can build period... Even if it's a stock engine.

So, what are you going to do with the bike?
If bikes are for kids I'll never grow up.

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