ITALKIT Top End Gasket Kit for KAWASAKI KX 500 1989-2004

On KAWASAKI KX 500 from 1989 to 2004, the ITALKIT VJ860VG810470 top end gasket kit fits in place of the original part. As soon as the cylinder head or cylinder is removed, their gaskets must be replaced: crushed when tightened, they have taken the shape of the parts and will no longer seal. This kit groups under one part number the gaskets needed to reassemble the top end.

Specifications

• Brand: ITALKIT
• Manufacturer part number: VJ860VG810470
• Engine: 2-stroke

When to replace it?

• Coolant or oil seeping at the head/cylinder or cylinder/crankcase joint.
• Coolant level dropping, bubbles in the radiator.
• Hissing or black marks where the exhaust leaves the cylinder.

At every piston change and every time the cylinder head or cylinder is removed, even for a simple inspection. Gaskets cost little compared with the work of stripping the engine.

Fitting tips

1. Clean the gasket faces without scratching them (plastic scraper, solvent): they must be clean, dry and free of burrs.
2. Fit the gaskets dry, without sealant, unless the workshop manual says otherwise.
3. Refit a base gasket of the same thickness as the old one, unless you are deliberately adjusting the squish.
4. Tighten the cylinder head in a criss-cross pattern, in several stages, up to the manufacturer's torque.
5. While it's apart, replace the spark plug and refill the coolant.
6. After break-in, check the torque with the engine cold and make sure there are no leaks.

Why ITALKIT?

ITALKIT is a Spanish manufacturer of engine parts for small-displacement machines: cylinders, pistons, crankshafts, reed valves and spare parts in several sizes. The brand is very active in 50cc racing, especially in Spain.

Spare parts and items to plan

• Piston : WOSSNER · WISECO
• Piston rings : WISECO · WOSSNER
• Spark plug : see the selection
• Coolant : LIQUI MOLY 1 L · TWIN AIR
• 2-stroke oil : LIQUI MOLY 1 L · LIQUI MOLY 4 L

Frequently asked questions

What does the kit contain?
Depends on the model. Compare with your original gaskets if in doubt.

Should I replace it along with the piston?
Yes: as soon as the cylinder head and cylinder are off, new gaskets go back on. It's the right time to fit a new piston kit and new rings if the engine has some hours on it.

Compatibility

Check the exact model and year of your bike in the list below before ordering.

Fits:
KAWASAKI KX 500 2004
KAWASAKI KX 500 2003
KAWASAKI KX 500 2002
KAWASAKI KX 500 2001
KAWASAKI KX 500 2000
KAWASAKI KX 500 1999
KAWASAKI KX 500 1998
KAWASAKI KX 500 1997
KAWASAKI KX 500 1996
KAWASAKI KX 500 1995
KAWASAKI KX 500 1994
KAWASAKI KX 500 1993
KAWASAKI KX 500 1992
KAWASAKI KX 500 1991
KAWASAKI KX 500 1990
KAWASAKI KX 500 1989