Kawasaki ER-5 / KLE 500 / GPZ 500 / EX 500 - Engine TEARDOWN - Part 7 Slitting the cases

[@taznz1]

Your right, the shift fork riding on the selector drum is very cool. Little details like this make watching you swear an old motorcycle engine for hours totally worth it. :) Keep up the great work.

[@SuperTelecom]

Jesus christ, I've only really worked on dirt bikes but that clutch chain is a beast. Thank fuck for direct gear driven clutches.

[@roidfingers]

Is it possible to change the piston rod bearings by just removing the oil pan?

[@dirtygarageguy]

Sorry mate you've lost me with piston rod bearings? If you mean the rod bearings then no you can't.

[@ynn321]

is it posible to replace the outputshaft oil seal without splitting the case?

[@erciyesceteci9242]

Mr.PonyPower can i get the bolt pattern that you have :), Regards.

[@dirtygarageguy]

+Erciyes Çeteci yes mate its here in the description of the 1st video kzbin.info/www/bejne/g5muZ6hrhbGKaLM

[@roidfingers]

Got a loud knock. seems to be coming from the left lower side of motor. Any thoughts?

[@dirtygarageguy]

No.1 how sure are you of the location? Engines have a habit of masking the source of a sound. Use a metal rod to help narrow down its location. No.2 Are both cylinders firing? No. 3 How many miles has the engine done? A little bit of history will help. No. 4 Worst case if you've thrown a rod bearing. If this is the case then the work required to repair it is quite substancial. Hope this helps - matt

[@roidfingers]

Yes both are firing. Have rebuilt he carbs and it runs smooth. Put a hose to my ear and sounds like lower left.

[@johnbogdaniec671]

must be -40 in the shop look all the oil has gone treacle eeeee!

[@forevercomputing]

Did you mean "Splitting" ?

[@bikersquest]

Any idea on how to prevent getting gungy oil in the sump like this bike did? I take it this happened due to the bike sitting for a while with the same oil?

[@dirtygarageguy]

+Bikers Quest pretty much yeah, I check the oil with a magnet then washed the oil down with petrol and poured it through a coffee filter and checked for ally shavings. Everything was good - but yeah the fatc that its been sat for 8 years getting hot and cold as the seasons passed cause the contaminated oil to coagulate. Modern oils have anti-foaming agents and detergents as additions to help clean particles within the engine, when these sit for years with contaminates within they coagulate to hold the particles. This forms a sticky crappy paste. This is why diesels needs different oil as the anti-foaming agent reacts with diesel and messes everything up. Cause the oil to turn into a tar like sustance. To answer how to stop this from happening, changing oil regularly is the best prevention. Using a thinner oil in winter also helps greatly, and reduces wear during the colder months. If a enigne is being used or not the oil should be changed every 6 months, filter included.

[@bikersquest]

Thanks for the clear explanation. I've been changing one early or milage whatever comes first basis basis :S

[@mariusm5187]

I would be too scared to hit anything with a hammer xD

[@dirtygarageguy]

+Mariusmssj M its a dead blow rubber hammer

[@mariusm5187]

+Pony Power ahh makes sense now :)