KX500 gearbox problem

**Stylo** · 6th July 2010, 19:45

Originally Posted by CHOPPA

Cool, im about to pull the engine apart now, I have just rebuilt the bike from the ground up so there are no worn out items except the footpegs as it seems they run 2 diff types.... Only thing i hadnt touched is internal engine as it was all ex japan, ill prob go aftermarket just always used oem so hopefully will be ok

I could just put it on my Mr Motorcycle 2 years interest free account?????

Been an owner/ rider and racer ( Offroad only ) of KX500's since 1997...all sounds a bit strange to me ! Still got one in my garage but, not sure if I can help .....

Couple of pic's to keep you going ......

**CHOPPA** · 6th July 2010, 19:48

Originally Posted by Brian d'marge

The thing that has me thinking is that you said it happened in every gear, the things that are in action in every gear are the primary drive ( associated bearings ) and the selector forks ( hard changing gear ) and the sprocket and that the sound is loud enough to hear in every gear

I am just concerned that ( hard to put feelings into words sometimes ) well its happening in all gears , and if dogs go then its difficult to get into gear etc and its a clacking sound .... was there any other info , like low oil in gearbox ,

F5 dave I think shares the same concerns

anyway when you are going about replacing a bearing , most drive side bearings fail because of overtightened chains ( seems loose but near full compression the chain is rock solid , or fatties with standard springs,, again tightening the chain , kills the seal, grit , dirt , and sionara bearing

Even the power washer , nice and clean , removes all grease , sionara bearing

Anyway off topic , you dont have to put the same bearings back, you can get ( for the same dimensions ) a better seal and load carrying abilities , ( your bearing suplier can help , if you know the approx load )

Hope you get it all back together

BTW The Ruapuna round was shown briefly on Japanese TV ( I think it was Ruapuna as it was a few seconds early in the morning , if you were wearing blue and white leathers and have very short hair , then you have 14 min and 30 seconds of Fame left to use

Stephen

ps keep us posted

Yeah very short hair haha I have the engine apart now and the gearbox and associated bearings look and feel mint however the LH crankshaft bearing is very noisy so im figuring this was the problem, not sure why i would only be able to hear it under load and not just by revving it but ill replace everything anyways

**CHOPPA** · 6th July 2010, 19:52

Originally Posted by Stylo

Been an owner/ rider and racer ( Offroad only ) of KX500's since 1997...all sounds a bit strange to me ! Still got one in my garage but, not sure if I can help .....

Couple of pic's to keep you going ......

Just a tad jealous.... Ive had a CR500 as well, just like green bikes I guess. I wreck every bike I ride, just unlucky I guess but ever since I was 8yrs old I have killed clutches and gearboxes. I think its cause i learnt to ride on a kx80 that had good bottom end power then when i started to ride better we went to hondas that had no bottom end power so it was full throttle slipping clutch style that I have never been able to shake, even on a superbike hahaha

**Brian d marge** · 6th July 2010, 20:23

Originally Posted by CHOPPA

Yeah very short hair haha I have the engine apart now and the gearbox and associated bearings look and feel mint however the LH crankshaft bearing is very noisy so im figuring this was the problem, not sure why i would only be able to hear it under load and not just by revving it but ill replace everything anyways

the loading is different

Check seal on cover to make sure crap isnt getting in.

Still curious about clack clack , was it engine speed or rear wheel speed ie if in a different gear did the sound seed up or slow down

curiouser and curiouser

Stephen ( off to watch Top gear no 2 ~)

**CHOPPA** · 6th July 2010, 20:37

Originally Posted by Brian d'marge

the loading is different

Check seal on cover to make sure crap isnt getting in.

Still curious about clack clack , was it engine speed or rear wheel speed ie if in a different gear did the sound seed up or slow down

curiouser and curiouser

Stephen ( off to watch Top gear no 2 ~)

It was while on the gas, once i backed off it would go away....

**Stylo** · 6th July 2010, 20:59

Originally Posted by CHOPPA

It was while on the gas, once i backed off it would go away....

All good, take it easy and, good luck with your 500 mate.....

Nothing beats a Bike that'll lift the wheel in top gear .........

Don't make 'em anymore Dammit
Shame

**theblacksmith** · 6th July 2010, 22:16

SMP in Frankton are very well priced for bearings Choppa.

**Crasherfromwayback** · 7th July 2010, 08:18

Originally Posted by Stylo

Nothing beats a Bike that'll lift the wheel in top gear .........

Don't make 'em anymore Dammit
Shame

450 four strokes wheelstand in top gear no worries at all. They hook up better than 500 two strokes and are easily as fast in the dirt. On tar for that matter too.

**CHOPPA** · 7th July 2010, 09:43

Originally Posted by Crasherfromwayback

450 four strokes wheelstand in top gear no worries at all. They hook up better than 500 two strokes and are easily as fast in the dirt. On tar for that matter too.

It seems even smaller capacity 4 strokes like the KTM SXS350 are doing the deed on the world stage, i still think something like this would be fun!

http://servicehonda.com/kawasaki-201...onster-kx500af

**Crasherfromwayback** · 7th July 2010, 10:16

Yeah...although I think the 350's will be even higher maintenance than a 450.

That looks great I reckon...and I still do love 500 strokers.

**barty5** · 7th July 2010, 14:16

problem with the 350 is its down on power but still wights in around the same as a 450

**CHOPPA** · 7th July 2010, 16:59

Originally Posted by barty5

problem with the 350 is its down on power but still wights in around the same as a 450

Yeah im all for more power!!!!

Id have one of these all day.....

700cc 2 stroke 90hp oh yeah!!! It would make a loose supermotard as well

http://www.maicointernational.com/index.html

**Ride it till the red** · 7th July 2010, 17:48

Originally Posted by barty5

problem with the 350 is its down on power but still wights in around the same as a 450

Thats not the point, it feels lighter to ride... Crank inertia, power delivery etc etc..... Just like the 250's aren't THAT much lighter yet they feel so much lighter when riding.
And lets be honest, most people can't use nearly what a 450 can give. Hence why most people can ride a 250 faster........
350 IMHO would just give it that little bit more pull that you can sometimes long for on a 250

**oldguy** · 7th July 2010, 18:16

Originally Posted by CHOPPA

It seems even smaller capacity 4 strokes like the KTM SXS350 are doing the deed on the world stage, i still think something like this would be fun!

http://servicehonda.com/kawasaki-201...onster-kx500af

you could always try shoe horning your motor in to a 2010 450 frame

**CHOPPA** · 7th July 2010, 19:32

Originally Posted by Ride it till the red

Thats not the point, it feels lighter to ride... Crank inertia, power delivery etc etc..... Just like the 250's aren't THAT much lighter yet they feel so much lighter when riding.
And lets be honest, most people can't use nearly what a 450 can give. Hence why most people can ride a 250 faster........
350 IMHO would just give it that little bit more pull that you can sometimes long for on a 250

The 350 would be good for the new school try to scrub every jump rider thats under say 80kgs but for someone like me a bit old school id still be quicker on a 450. A 350 would getted waxed on the starts as well, it will be interesting to see how they go, more interesting how mid pack riders will do on them rather then the team supported guys

Originally Posted by oldguy

you could always try shoe horning your motor in to a 2010 450 frame

Id love to do that! Im short of around 10k or so....