Chads 92 KX500 engine Build

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Well.... I didn't get pics before we started but at least I got a few after we got started.
A little background...
On the Cylinder we did all the Kawasaki Team Green mods plus a few.
Stock Port timing.
Cylinder was then sent to Millennium for plating.
Wossner Piston.
Head squish and compression release mod was done by Roostius.
Cases were stripped and Vapor Blasted.
Then all the oil gallies were cleaned up and the cases were lapp8ed with time saver.
We ordered the following internal parts:
92028 BUSHING 92028-1551
92046 BEARING-NEEDLE 92046-1193
92022A WASHER,22.3X38X3.0 92022-1832
92022 WASHER,22.5X46X2.6 92022-1739
92045 BEARING-BALL,6001C3ML01 92045-1235
92022C WASHER,12.3X20X0.5 92022-269
92022B WASHER 92022-1942
(3) 92045 BEARING-BALL,608MC3 92045-1305
59051 GEAR-SPUR,WATER PUMP,11T 59051-1129
92028 BUSHING,26X35X14 92028-131
92045 BEARING-BALL,6305 92045-1011
92045B BEARING-BALL,63/22T2C3 92045-1134
92045C BEARING-BALL 92045-1233
92045D BEARING-BALL,608MC3 92045-1305
(2) 92046 BEARING-NEEDLE,HK1210 92046-1010
92055-1343 O-RING
(2) 92046-1052 GOVERNOR BEARING
(2) 92045-1027 BEARING
(2) 92055-035 ORING
92045-036 BEARING
92045-1235
92022-1942
92022 WASHER,17.3X28X1 92022-255
92033 RING-SNAP,24MM 92033-026
92033A RING-SNAP,18MM 92033-029
(6) 92033B RING-SNAP,25MM 92033-1089
92046 BEARING-NEEDLE,KT202614 92046-1170
92143 COLLAR,25X32X10.5 92143-1370
KICK START SPRING 92081A SPRING 92081-097
(4) 92042-007 PIN DOWEL 6.3 X 8 X 14
(5) 610A0408 ROLLER 4 X 8
(2) 482J4000 CIRCLIP SELD BEM FIT
"0" RING 92055-025
Wossner rod kit
Rebuild, Weld, True, and Balance to 59% by Pinsonnault Racing.
Koyo Crankshaft main bearings and seals
Cometic bottom end gasket kit
The exhaust valves were junk but luckily I had a set.

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Here is a few pics of where we are at.

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93 kx500 chad engine buils 103.jpg (101.57 KiB) Viewed 8379 times

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Another modification we did was swap out Chad's pre 94 shift shaft for a 94-04.

93 kx500 chad engine buils 104.jpg (85.5 KiB) Viewed 8372 times

Why?
He wanted to use a newer style shift lever from a KX450F

93 kx500 chad engine buils 105.jpg (22.87 KiB) Viewed 8372 times

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A nice carb cleaning..

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93 kx500 chad engine buils 108.jpg (79.38 KiB) Viewed 8368 times

93 kx500 chad engine buils 109.jpg (60.3 KiB) Viewed 8368 times

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Getting closer...

93 kx500 chad engine buils 110.jpg (74.78 KiB) Viewed 8354 times

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93 kx500 chad engine build 113.jpg (165.99 KiB) Viewed 8349 times

93 kx500 chad engine buils 113.jpg (120.19 KiB) Viewed 8349 times

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1st heat cycle is done...

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One full tank is through it...
Chad says it has amazing power....
We knew that

[Bix Weir]

Great job guys.
That engine looks beautiful!

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You can see this bike in action here:

https://www.youtube.com/watch?v=92SOJIXTL0w

https://www.youtube.com/watch?v=jedeQww0_Os