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Old 12-30-2009, 10:00 PM   #1
mcd
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kx65 rebuild progress

Started on my kx65 rebuild today (Thanks to Thomas' post reminding me to get with it!).

Basic disassembly today. Got the motor out of the frame and the main parts out of the way on the chassis. Hopefully I will get to tear into the motor tomorrow, and see what lies in store. Once I get the motor apart, I will be putting my order in for parts. Also need to rework the rear shock and front forks while waiting on motor parts. Front brakes will receive race pads and new fluid.

I will say that pulling the motor out of the little kx was much easier than the 450! Very little persuasion and it was out. Although I do have a pretty substantial size advantage on the little thing!
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Old 12-30-2009, 10:27 PM   #2
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please let me know how that goes for you. i really wanna get on mine instead of paying somebody some outrageous money to do it. im sure this wont be the first time i have to rebuild so i would like to figure it out now. thanks and keep the updates coming
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Old 01-04-2010, 07:55 PM   #3
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Got the motor stripped down to the cases. Cylinder and piston off, clutch off and apart, and all the gears for the crank, water pump, trans and kick starter removed.

So far it has been a pretty smooth tear down. Need to get a puller to split the cases, hopefully tomorrow. Ordered a new Wiseco crank kit, and will be ordering an OEM top end to go back together.
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Old 01-04-2010, 08:03 PM   #4
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glad to see its working out and you make it sound pretty simple. is a puller pretty much the only special tool you will need? thanks for the update
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Old 01-04-2010, 08:58 PM   #5
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Impact wrench, three jaw puller and harmonic balancer puller are the only "special" tools I have needed so far.

Getting the crank and main bearings in sounds like a little bit of trickery with heat and cold, but doesn't sound too bad.
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Old 01-24-2010, 09:37 PM   #6
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any updates??
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Old 01-25-2010, 02:42 AM   #7
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Been away at work for the past 3 weeks.

Parts have been ordered, and should have all arived for the motor.

When I get back in a few days I will be splitting the cases and putting it all back together. Hope to have it back running by the first of February.

I will let you know how it turns out.

Go ahead and pull your motor apart, it really isn't bad. Splitting the cases will be the most difficult part, but I am going to rig up a harmonic balancer puller for that. Once I get all the needed bolts, you can borrow them to split your cases.

I got a good set of instructions on how to get the new crank and bearings in. Should not be too much of a struggle.
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Old 01-25-2010, 10:51 PM   #8
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where did you order the parts? is ebay the cheapest you found? i have read tons on this and im ready just nervous about it. lol thanks for the info and let me know how it goes
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Old 01-26-2010, 12:53 AM   #9
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Got the crank kit off ebay, and the top end through service honda.
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Old 01-26-2010, 01:00 AM   #10
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User is banned

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Old 01-26-2010, 01:05 AM   #11
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i pulled my crf450 motor out to have the top end rebuilt i even took the valve cover off and it was still a to get out, especialy with that tubing that goes above the head that is conected to the frame
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Old 02-03-2010, 08:44 PM   #12
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Got the cases split this evening, and got the motor torn down to the bare cases.

Splitting the cases was fairly simple, and getting the crank/main bearings out was easier than I expected.

Hopefully I will be going back together with the motor tomorrow. Everything looks good inside, and all my rebuild parts have arrived.

Glad I decided to replace the crank and main bearings, even though they appeared fine. The mains had some signs of overheating, and I am sure that they were on there way to locking up at the most inconvenient time!
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Old 02-03-2010, 08:55 PM   #13
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nice...how do the bearings come out? Are they pressed in?
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Old 02-03-2010, 11:10 PM   #14
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man i am glad you got it all figured out!!! lol and im glad i live right up the road from you. i just pulled the motor out of mine and my crank should be in on friday. still have to get the top end ordered. hopefully a local shop may have it in stock. so when you get yours all put back together let me know when i can drop mine off for you thanks in advance. lol
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Old 02-08-2010, 05:54 PM   #15
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Got it all buttoned up and fired it up today. Runs strong and sounds good.

Next step is some motor tuning and chassis set up.
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Old 02-08-2010, 05:55 PM   #16
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Quote:
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nice...how do the bearings come out? Are they pressed in?
Yes, bearings are pressed into the case, and crank is pressed onto the main bearings. Real PITA!
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Old 02-08-2010, 09:07 PM   #17
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I ended up getting the hot rods crank and a stock top end. should start working on it soon.
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Old 02-09-2010, 09:48 AM   #18
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Quote:
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I ended up getting the hot rods crank and a stock top end. should start working on it soon.
Let me know if you need any advice. Pretty straight forward, although putting the mains and crank in can be a little tricky.
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Old 02-09-2010, 10:33 AM   #19
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keep it up man! I have a kx60 im about to start really tearing into and would like to see how others handle that lil beast
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Old 02-09-2010, 10:40 PM   #20
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My big deal on the KX65 is what to do with the rear shock. I have enough money in places right now that I cant just go buy an ohlins or other expensive shocks. So I need to figure a way to make the stock shock work for now.
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