are you sure it isn't stuck in the lifter? mine was, it built up some sludge that kept it in there.kkvslayer wrote:also I forgot to mention there was no ball bearing in the clutch assembly
Finally tore down my engine(pics)
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
I'll check later,but i'm pretty sure there was not one in theredannygraves wrote:are you sure it isn't stuck in the lifter? mine was, it built up some sludge that kept it in there.kkvslayer wrote:also I forgot to mention there was no ball bearing in the clutch assembly
1994 Heartless CR500R
1986 KX500
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
if you can't find clutch parts, I have a bunch of them. I converted mine to a 90+ clitch and t/o bearing and complete side cover.
The only part I don't have is the center hub.
The only part I don't have is the center hub.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
of coarse if you have the green I would recommend doing what I did. Not only is the clutch pull a lot lighter, but the operation is smoother. Most importantly the parts are available. I couldn't find the center and I wanted to replace my corroded waterpump anyway. I bought all the parts to do the conversion used from a guy parting out a '93 for like $100+shipping. Now if I break something I can find it easily. If I notch up this basket I can go buy a hindson which I couldn't do with the old one.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
There is a hinson clutch basket available @ dennis kirk and I saw one on ebay earlier,That thought of changing to the newer side cover and clutch is already in my mind,I wouldn't even mind buying a complete engine right now if the price was right.dannygraves wrote:of coarse if you have the green I would recommend doing what I did. Not only is the clutch pull a lot lighter, but the operation is smoother. Most importantly the parts are available. I couldn't find the center and I wanted to replace my corroded waterpump anyway. I bought all the parts to do the conversion used from a guy parting out a '93 for like $100+shipping. Now if I break something I can find it easily. If I notch up this basket I can go buy a hindson which I couldn't do with the old one.
1994 Heartless CR500R
1986 KX500
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
you have to remember that IF you do buy a whole motor and it is newer than '88 the swingarm bolt holes will be 2mm larger and you headstay won't fit and you will have to use the carb boot from the old motor.kkvslayer wrote:There is a hinson clutch basket available @ dennis kirk and I saw one on ebay earlier,That thought of changing to the newer side cover and clutch is already in my mind,I wouldn't even mind buying a complete engine right now if the price was right.dannygraves wrote:of coarse if you have the green I would recommend doing what I did. Not only is the clutch pull a lot lighter, but the operation is smoother. Most importantly the parts are available. I couldn't find the center and I wanted to replace my corroded waterpump anyway. I bought all the parts to do the conversion used from a guy parting out a '93 for like $100+shipping. Now if I break something I can find it easily. If I notch up this basket I can go buy a hindson which I couldn't do with the old one.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
'87 is everyones fav year. great power like the older ones, but it uses the new rod and the newer ignition and still has a wide ratio trans ('88 went close ratio). But it still uses the old clutch and the old countershaft so the c/s sprockets are still a little harder to find.
What year is your bike anyway? for some reason I want to think its an '86.
if it is '86 or older and you find that you need to rebuild the crank you may have to get an '87+ rod kit and put a spacer under the cylinder.
What year is your bike anyway? for some reason I want to think its an '86.
if it is '86 or older and you find that you need to rebuild the crank you may have to get an '87+ rod kit and put a spacer under the cylinder.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Your right its a 86dannygraves wrote:'87 is everyones fav year. great power like the older ones, but it uses the new rod and the newer ignition and still has a wide ratio trans ('88 went close ratio). But it still uses the old clutch and the old countershaft so the c/s sprockets are still a little harder to find.
What year is your bike anyway? for some reason I want to think its an '86.
if it is '86 or older and you find that you need to rebuild the crank you may have to get an '87+ rod kit and put a spacer under the cylinder.
1994 Heartless CR500R
1986 KX500
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
I wouldn't be surprised, most of the parts that are pre '87 are unavailable, or it will say that it is, but they just send you the newer vesion which doesn't fit. I've heard of people buying the old clutch basket from SH and receiving the new one.kkvslayer wrote:I'm looking @ a parts fiche and it says the mainshaft fifth gear is N/A,is this true?
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
I can't remember which gear, but I'm assuming its the largest main shaft gear. if you go here they show an updated p/n, maybe they made some changes to it in '87
http://www.mrcycles.com/fiche_select.as ... onda#SDOWN
http://www.mrcycles.com/fiche_select.as ... onda#SDOWN
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
How much does it cost for a resleeve,new piston kit?AlisoBob wrote:Good call Mike.... notice the reveal on the combustion chamber too.97af wrote:Maybe its the picture but that cylinder sleeve looks really thin.
2MM over maybe?
KKV, I know your in the middle of "Nowheresville"....
How close is the nearest machine shop?
( or UPS depot?...... )
1994 Heartless CR500R
1986 KX500
Like any journey, you need to know where your starting from....
Thats why I asked you if a machine shop is near by...
It could be as simple as:
1. Have bore measured, and find out its within spec.
2. Have head opened up to match bore oversize.
3. Order piston kit of the proper size ( the whole kit should be about $150)
Reassemble.
OR, your may find that the bore is junk, and you are at the last oversize. A new jug from S/H is about $260 last time I checked...
OR, you may find yourself somewhere in the middle....
Measuring the bore is the first step in any scenario....
Resleaving , in my opinion, is a poor option. Go with the new jug. Its like $20 more when all is said and done.
Thats why I asked you if a machine shop is near by...
It could be as simple as:
1. Have bore measured, and find out its within spec.
2. Have head opened up to match bore oversize.
3. Order piston kit of the proper size ( the whole kit should be about $150)
Reassemble.
OR, your may find that the bore is junk, and you are at the last oversize. A new jug from S/H is about $260 last time I checked...
OR, you may find yourself somewhere in the middle....
Measuring the bore is the first step in any scenario....
Resleaving , in my opinion, is a poor option. Go with the new jug. Its like $20 more when all is said and done.
Last edited by AlisoBob on July 5th, 2007, 3:48 pm, edited 1 time in total.
so you guys think my piston is too big or too small for the bore?AlisoBob wrote:Like any journey, you need to know where your starting from....
Thats why I asked you if a machine shop is near by...
It could be as simple as:
1. Have bore measured, and find out its within spec.
2. Have head opened up to match bore oversize.
3. Order piston kit of the proper size ( the whole kit should be about $150)
Reassemble.
OR, your may find that the bore is junk, and you are at the last oversize. A new jug from S/H is about $260 last time I checked...
OR, you may find yourself somewhere in the middle....
Measuring the bore is the first step in any scenario....
Resleaving , in my opinion, is a poor option. ^o with the new jug. Its like $20 more when all is said and done.
1994 Heartless CR500R
1986 KX500
If my bore was Too small wouldn't it have seized or have more scuff marks or if it was to big wouldn't there be more blowby because it looks very clean with a few scratches and the one little scuff thats showing in the pic.AlisoBob wrote:I have no idea... this is what YOU need to find out.
Once you find out about your "Bore Size", you can proceed in the correct direction.
1994 Heartless CR500R
1986 KX500
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
the easiest thing will be to look at the numbers on the piston. if it says 1.00, then buy a 1.5 piston and send them together to the machine shop. if the piston says 2.00 (last over bore) see if the new cylinders are available ('85 and '86 are the same, the '87 and '88 saw changed to timing, but will work)
the number is on the top middle of the piston.
the number is on the top middle of the piston.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
thats what I thoughtou812 wrote:85-86 barrels are not avalible, get a sleave and press in
Last edited by dannygraves on July 6th, 2007, 6:19 pm, edited 1 time in total.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
like I said, if you don't have any way to acurately measure, look at the numbers on the piston, as long as it isn't 91mm or 2.00mm over (.080") then you can just go one more over. no one will be able to tell you the bore size by looking in the picture. it looks thin, but you might just me at 1.5mm over which would give you a full aditional bore. no one can tell you the difference between 1.5mm and 2.0mm through a picture.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80