WE BROKE OUR YZ500 BUILD… Not good 🤦♂️ (in the middle of a magazine test) | 2023 Yamaha YZ 500
You read right… Join me on a week long adventure filled with ups, downs, great company with my Build Team Members, and failures we can only come back stronger from!
Thanks for watching, guys!
🔥 CHECK OUT YOUR MC500 BUILD UP CLOSE, PERSONAL & BEHIND THE SCENES HERE:
-mXrevival Instagram – https://www.instagram.com/mxrevival/
-mXrevival TikTok – https://www.tiktok.com/@mxrevival?lang=en
-mXrevival Facebook – https://www.facebook.com/mxrevivalonline
Complete MC500 playlist – https://youtube.com/playlist?list=PL_oYXNbYADbIc12idhU4UH2vU8NXjUhlZ
#mXrevival #YZ500 #YZM500
![🏆스스로 증명하는 최강자🏆GTOUR의 새 역사를 쓰고있는👑김홍택👑[샤브올데이 GTOUR MIXED 2차대회]](https://www.fogolf.com/wp-content/uploads/2025/08/1755603128_maxresdefault-770x515.jpg "🏆스스로 증명하는 최강자🏆GTOUR의 새 역사를 쓰고있는👑김홍택👑[샤브올데이 GTOUR MIXED 2차대회]")
41 Comments
Need to get a solid shaft made up by an engineering shop and send it for hardening
Hmm , a 250 kickstart shaft won’t stand up to a 500 compression stroke . Good to know.
This whole build was about the shaft.
Put a 01 Kickstart or put a steel rod down center. They are known to snap.
It just needs dialed in. This will be an awesome bike eventually.
Very cool experience and it was so cool to meet Charles, Mark and Ron at Dirt Bike, Travis with his awesome pics and videos and cross-cup observations, Jay Clark, Rado and his son from Dirt N Iron, JB from JBI was so cool to talk to throughout the day and then got to meet Gary Jones and have him look at the bike and talk to him for a bit. I also fell over halfway up Mount St Helens in front of Josh Hansen on Charles' RMZ so that was also fun and not a good spot to crash.11/10 would recommend!
Great video!!! I really enjoy videos like this when you give us behind the scenes looks at some of the great people behind these builds and I really love that you shared the idea of the Gratitude Alarm!!! I am going to implement that!!! Maybe when you get everything ready to go you should deliver it to PA. I would make the trip to meet you!!!
I love your movies, err I mean videos. But, they’re just to damn long.
I like the longer videos. ! Good way to get my morning going. 👌thanks for taking us behind the scenes Charles. Getting to see what kind of guy JB is , makes me wanna send all my suspension work to him. Good luck with that damn kicker 🤟
Just a heads up on the Dunlop stickers you need to run them and create friction/heat for them to transfer and adhere properly. This was per dunlop themselves.
Great video, Sorry about your dilemma. Hopefully you can get the kick starter shaft issue resolved. I know the cost is huge but will the BRC kit accommodate an electric start?
🤘🤘🤘🤘
That weld came out nice 🤙🏼 glad you got her Rippin' man! 🙏🏼 Awesome job by everyone who had a hand in it. I've gotta get my dang 05 kx 250 suspension sent of to JBI and ask for some of that sweet lookin' red tube coating
Brilliant on JBI with the try it out method!
I’d love to see one of these turned into a street legal, by Dirt Legal, Supermoto. That would be sick. Imaging rolling up to the Rock Store, on Mulholland on a crowded Sunday, on one of these.
All of the dick jokes are freaking hilarious! 😂
I hope BRC find a solution. Didn't see enough of it in action!
Someone should have a shaft made from better quality material as that one was only designed for a 250
Another great video!!! I'd love to see the BRC500 shootout in Dirt Bike Magazine!
What's that thing that always seem to happen?? Either way Charles, great job on the build!
Minor set backs happen, awesomeness is forever! The YZ500 is cool as foooooooooooook!
You killed it on this build and great job rolling with the punches on the trip.
No YZ- 500cc! Yamaha = personal Japanese name! Makes it illegal – and label it – Yamaha.
And Yamaha – help get rid – "of Dirt Bike – mag(magic – piracy Co.)! Hamaha = feminine verse.
You cannot bore, any 250cc – into 500cc. 125cc = 750cc bore? But don't – work as. You masked – out the, real people? Key = EO Piracy
That's just how it goes with 500's if parts are not vibrating off they are braking. But its worth it when you get to ride one.
Gratitude alarm is a fantastic tool … I need one!
500 compression just to much for that hollow shaft ….may have to go to solid billet …..i have a question i hope you will take the time to answer ….i have an 06 WR450 (steel frame) that is my baby….question is …..will the new plastic kit you used on this bike work on my 06 WR450F …..i have all new plastic ….but would love to know if and what i would need to buy to do this to my bike ….ps think its super nice of you to put all that work in and give the bike away ….says alot about your character…..so i subscribed and gave you big thumbs up
I believe this was an issue in this year of bike.. I had it happen to me back then with the 250 motor and to fix and prevent it happening again I put the kickstart shaft, the crankcase cover and kickstart off a 2001 bike. The shaft is a lot thicker on the 2001 bike and everything I bought just bolted straight on. Maybe an option? The 500 could use the bigger kickstart shaft, but the crankcase cover could be an issue.
A little Tip, You should NEVER start a 250 or larger engined bike on a bike stand. When the lever hits the peg it’s just a hard stop and the only weak links are the primary cover and kickstart shaft. When you have the bike off of the stand, your suspension can absorb some of the shock that would normally be pinpointed on the shaft and case!
Us old-school guys are well aware of these issues.
Ace work just fucken AWESOME!!!!! from Aus btuz!!!
My 1991 KTM 540 DCX never broke a kickshaft, nor did it have a compression release. It might have had a solid shaft, but I don't remember. Is the break occurring on kickback, ie. the timing is off?
Charles, the earlier 00/01 Kickstart shafts were 20MM vs yours at 18MM, maybe you could also have a machineshop re-inforce the insides with a smaller shaft and weld it up.
The BRC kit is flawed in a number of ways.
First off, its a 500cc engine/power on a transmission designed for a 250cc engine. The size & durability of the parts are not designed for the that big of an engine. The gear ratios are not optimally spaced for the power of a 500cc engine & again, are undersized. When you have a cr500 or kx500 teansmission apart, you can see both the gears, bearings & shafts are much bigger in a real 500 engine. Obviously, the kick start isn't up to the task either.
The BRC port layout is not sorted very well either.
The Lectron & Smart Carbs are also a poor choice. They lose power vs the Keihin & Mikuni. The claims that they dont need to be tuned once set is also a total myth.
Lastly, the BRC power claimed by BRC is WAY over inflated. They are about 52-53rwhp.
Not hating, just saying. Facts are facts. Facts, dynos & failing parts don't care about peoples feelings. So if anyone has their panties in a bundle over what I shared, get over it. It is what is what it is.
Now you know why CR500s had flutes cut into the cylinder to bleed off compression when kick starting. I had one and remember learning the procedure to kicking that big bastard.
Love to see how the magazine guys acknowledge the professionalism, passion and attention to the details you put in your creations. Un fuerte abrazo friend!
I think the hollow shaft is undersized for the 500cc.
Probably the hollow shaft is also hardened too hard and breaks because it is not elastic.
I don't think a full shaft is the correct solution.
The outside diameter cannot be increased because it is limited by the clutch cover measurements.
The best solution would be to make a new clutch cover, or modify the existing one, to allow bigger diameter but it is almost impossible to practice.
The solid shaft doesn't convince me, the hollow shaft is more robust.
The only solution is to decrease the internal diameter, changing the type of steel and make a less exaggerated hardening.
Consider having a hollow shaft built ex novo.
This is according to my experience.
You need to put a 2001 yz250 clutch case and kickstart shaft on it it's bigger shaft and takes a yzf450 kickstart
Dude love that you show the behind the scenes stuff, bad and all (JBs shop looks amazing, cool dude). Just have that much more respect for you and the awesome people you work with. You got the grit when things get tough to keep pushing forward, shit happens, but it's how you handle it when plans go sideways that matter the most. Adds to the suspense!! Great content as always!! Can't wait to see this baby flying!!!
Gotta say broken kickstart shafts make me worried for how the electric start is going to hold up on the mc500😢
Have you been using the compression release when starting it?. I always use the compression release on my KTM BRC 500, Riley is a fan of the compression release making life easier on parts. Also wondering it you can Machine a plug to press into a kicker shaft to reinforce it. EDIT: Continuing through the video I see see you were using it.
When you do the next BRC build on the Austrian bike you can install an electric compression release. I wired mine so when I hit the starter button it just actuated, I also wired a button in case I wanted to use the kicker. Also the kicker kit for the 300 has a tiny kicker and you can use the full size kicker with a little messaging.