KX500 Engine Rebuild

In Part 3 of our massive KX500 Project build we finally get the engine back together. Enjoy some big two-stroke motor action.
Jay Clark/Dirt Bike TV has been around the Dirt Bike industry for thirty years and is always looking to learn and help other do so as well. Give a follow or drop a email if you have any questions or comments. Thanks for watching!
Instagram: @dirt.bike.tv
Facebook: / dirt.bike.tv
KZbin: / dirtbiketv
Website: jayclarkent.com
Email: [e-mail]
Thanks for watching, don’t forget to share and subscribe.
#kx500 #kawasaki #2stroke #twostroke

[@leadhead7338]

Team Green.... Always!

[@dirtniron]

looking good guys!

[@evo5349]

Brads the Man!

[@zackcarpenter5936]

between this dude flying through building the engine and him using an impact to tighten bolts, my anxiety is through the roof

[@jmueller9504]

Yea how many real professionals were saying OH MY GOD NO NO NO NO I could build 2 more engines with all that extra case sealant 1/2 in gun for clutch nut , well it didn’t strip so I guess it must be tight Wtf is with the torch and socket NO NO NO So many wrong procedures

[@JimEckert]

Oh and Brad is Rad!!!

[@WujoCaZa]

Great. First mechanic who doesn’t use direct fire on inner race bearing 🦾

[@aidanvelthuis1267]

I’m putting an engine together tomorrow, is there an issue with using direct flame? I legit have no idea

[@WujoCaZa]

@@aidanvelthuis1267 dont know exactly. Maybe with the direct fire you don’t have control on heat expand. Bearing is not designed to take direct fire. Only heat expand. Trust me I fuck**d up may bearings with that method 🤣

[@rcuniversespeed9447]

Yeah no need to use direct flame you can use a thermal heat gun just get it up to 220 a digital laser thermometer helps quite a bit

[@xxkawboyxx6983]

Im building a kx500 engine thats been sitting for 15 yeara in a box this really helped thanks a lot!

[@coloradodirtbike5930]

I like the decompression head. Everything looks great, wonderful job and rebuild. Can't wait to see it ripping around

[@rcarle]

Looks great. Brad is a stud.

[@fuellerr]

The motor looks SICK with the different color head and clutch cover

[@welderjedi5145]

Dude is lightning!

[@TheCarlejoseph]

Looks amazing! Nothing better then bringing an old bike back to life and better then new.

[@Pedrofs001]

Killer build!

[@saraclark8966]

So much work to put an engine back together! Good job !

[@vince5946]

Sweet, great job once again Brad. I had an 88 CR 500 back in 90 and started that thing 1 time with tennis shoes on, foot still aches today LOL :). If you've ever had a big bore 2 stroke kick back it'll damn near kick your but over the bars and man can it hurt/break your foot. But man once they fire hang on, what a blast.

[@robertwoods2505]

Absolutely beautiful engine! Great job!!

[@dr.hugog.hackenbush9443]

I must be the only person left that can kickstart my 500s without a decomp head mod...

[@russellhelms2835]

Ha ha, nope me too😁1988 KX500. Still love it!

[@gavinbritt1349]

I know this guy has been doing this for a long time and knows what he’s doing doing but he makes me nervous 😂🤷🏼‍♂️

[@rcuniversespeed9447]

Very helpful Tom Morgan just sent me mine and I’m gonna be putting it back together here in the next few weeks thank you for the details and I’ll be following this video as well as others.

[@jonathondavis170]

Can't wait to watch more of this build!!! It is already a masterpiece with the engine! You were made for these machines...a very brilliant and talented man you are. Hope you have a great week! Catch ya next time. AWESOME project! 🤘💪🇺🇸

[@dirtbiketv1]

Thank you very much!

[@specbolt]

LOVE THE WAY YOU GUYS PRESENT THIS

[@APH.95]

I really want you guys do a AF build please please please

[@ianmangham4570]

I use to thrash a kx500 early 90s, she loved to wheelie all through the box till she hit near 80 mph then you gotta stop 😄

[@ianmangham4570]

Nice, sweet powerhouse of an engine 💪👍☇🙋

[@aidanvelthuis1267]

Quick word of advice. I am almost 100% sure that the mark on the oem Honda pistons for 2018+ faces the intake. Refer to service manual though

[@dr.hugog.hackenbush9443]

Arrow ALLWAYS points to the exhaust.

[@aidanvelthuis1267]

@@dr.hugog.hackenbush9443 not true. Oem Honda piston for the 2018-2021 crf 250r has a mark on it which faces the intake.

[@rootsofenduro239]

I hope that mechanic doesn't make love to a woman like he puts a engine together. Because she would be bruised and sore! Lol

[@JourdonGulick]

This is close to engine abuse 😂

[@laspar3462]

Yamabond all over the engine 🤮

[@kencarlton9939]

Using a impact to disassemble is one thing but, assembly is a big nono. Getting cocky without a torque wrench and specs is not cool no matter what you think you know.

[@bobaganooshy]

It's 30 years old jay, man your getting old

[@victoroneill4381]

I understand hes been working on this stuff for ever and obviously knows wat hes doing but geeze.

[@victoroneill4381]

Great thanks for that ill be splitting my 500 cases as the crank seal has gone bad.cheers

[@Mr10usdad]

Great video! I can tell you have done this before.

[@rafaelcordova6374]

Something about him using power tools instead of hand tools that made it hard to watch!

[@user-ch7rt8be1u]

Fc from Thailand

[@38possum]

Wished that dude was contactable I'd let him build my KX 500 motor

[@JimEckert]

Who the heck gave a thumbs down 👎🏿 that guy needs a broken leg from a 500cc without a decompression valve! Anyways if you need a test rider for that monster let me know.

[@dirtbiketv1]

😂😂

[@mikeking7388]

Not Brads first one lol

[@jonphotos8631]

❤️

[@Vince616]

I was watching this video to find out how to rebuild the clutch on my KX, you know where the washers and spacers went, what the torque settings were for the various nuts and bolts, the dude seemed to flash through it at double quick speed, missing out parts of the assembly, and the camera angles didn’t show anything about the assembly either, not a lot of help guys, and geez a ½ inch air wrench to hammer on the nut on the output shaft.

[@mikelyons469]

No BS there.

[@brianheikkila7761]

I have a kx 500 could you please give me the link for the two piece crank cover and also the decomp

[@dirtbiketv1]

email me - link in about- TMR does the head mod-- KX Guru on the other stuff

[@victoroneill4381]

quick question why shave the rubber pieces off the v-force reeds, thanks

[@dirtbiketv1]

No need--- email me

[@spencerclark2269]

Cool bike. Too fast for me

[@johngray722]

It’s 30 years old

[@VanekLarson]

Getting famous off comments day 185, so I can live the dream, live everyday like it’s your last day🤙

[@dirtbiketv1]

Legend!

[@rafaek673]

whats the best year crf to buy or ktm? pleeas tell me

[@dirtbiketv1]

This is a very touch question as each year and specific model can have issues. However, if you email me with anything your looking at I will be glad to give you a quick opinion--

[@victoroneill4381]

How long was the crank in the freezer,thanks

[@dirtbiketv1]

20-30 minutes I think is good

[@dr.hugog.hackenbush9443]

You can also heat the cases to 150° for drop-in crank& bearing assembly. I chill my cranks for 2 hrs minimum.

[@keithpeterson3447]

Way too much Yamabond. That delayed squeezing of the cases has a sideload on the crank main bearings.

[@hydro42060]

We're can i buy a kx500 notor

[@petergriffin4629]

2020-1991 = 20 years old ... yes somebody is still living in 2011😂

[@dirtbiketv1]

math can be hard when on camera LOL

[@petergriffin4629]

@@dirtbiketv1 i appreciate it, I still often think the 80s are 20 years ago. But absolutely incredible work. A bit like one of those japanese craftsmen, but with an all american twist!

[@silvanbeppigno4050]

I motori si chiudono con la chiave dinamometrica, non con la pistola pneumatica !!!

[@tagzproducts1497]

sponsored by vertex and using a wossner piston...

[@dirtbiketv1]

ya no Vertex option

[@broski925]

Why is this guy all .... twitchy? 😂

[@zrkn1]

I think he doesn't like to be on camera maybe, some people don't.

[@dr.hugog.hackenbush9443]

Meth

[@jahritaha5118]

I DONT LIKE THIS VIDEO... MORE MORE TALKING....