The 10+ year KX500 rebuild thread

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Bigyin
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Re: The 10+ year KX500 rebuild thread

Post by Bigyin »

derek badger wrote: Sat Jan 02, 2021 10:11 am
I'll crack on with the paperwork to get it registered next week.
Just quoting this so that when a squirrel goes past the garage and your attention span drifts we have something to point you back to ;)

Could it finally be finished ?, really? actually done?

time to break out one of weeksys new smilies

:banana-wrench:
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Re: The 10+ year KX500 rebuild thread

Post by Skub »

A mate had one of those a few years ago. I asked him was he not wary of it on the dirt,he said nah,just pin it and hope tae fuck it never gets grip. :shock: :lol:
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Re: The 10+ year KX500 rebuild thread

Post by demographic »

Vibration...
Expansion chamber mount to the frame, under the tank.
They always break. Without fail. Or with fail, depending on your point of view.

There's a kit of parts you can weld on to stiffen and strengthen the frame.
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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

Just paid Kawasaki Motors UK £54 for 'certificate of newness'. This basically is an official letter stating the year of manufacture and class of vehicle. The DVLA (and possibly the NOVA database) require this to register the bike and avoid a Q-plate. I've also stamped up a strip of aluminium with the VIN number and fixed it to the headstock. Even though the original is there and is readable, it's been painted a few times and this should keep my friendly MOT tested happy.

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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

Arrived in the UK with the guy yesterday. He UPS'd it to me straight away and it arrived 20 minutes ago. :thumbup:

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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

Result.

The statement that says it was originally supplied in the UK should mean I don't need to go through the NOVA stuff as it's not been imported.

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Re: The 10+ year KX500 rebuild thread

Post by cheb »

That's good. I found the DVLA to be efficient when I had to register the TDR and then the DTR,
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Re: The 10+ year KX500 rebuild thread

Post by Asian Boss »

Don't worry about all that paperwork bollocks, get it up on t'back wheel. :thumbup:
To a kid looking up to me, life ain't nothing but bitches and money.
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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

cheb wrote: Sat Jan 09, 2021 12:27 pm That's good. I found the DVLA to be efficient when I had to register the TDR and then the DTR,
I've done a motox bike in the past, but it's changed slightly. Back then I had to go to the local office to submit the paperwork.
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Re: The 10+ year KX500 rebuild thread

Post by cheb »

It was all by post for me, all documents and photos on paper with some money.
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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

https://www.ebay.co.uk/itm/Xt350-Superm ... 890.l49292

Stuck a drunken bid in on these and won them! 👍


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They were on a XT350 which shares the same 15mm axle as my KLR650 forks. The rear will need a bearing swap or some top hat spacers.

The will certainly look better than the mismatched road bike wheels on there and for a ton if I can't make them work I should get my money back punting them on again.
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Re: The 10+ year KX500 rebuild thread

Post by Skub »

Magic. I kinda miss drunk ebaying,but my bank account is less stressed. :lol:

That full on feeling of, 'don't know if I've done a bad thing or a good thing',mix of fear and excitement when looking at the next day's emails. :shock:
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Re: The 10+ year KX500 rebuild thread

Post by cheb »

Captive spacers for the win. Maybe not the win, but a lot less cursing when putting the wheel back in.
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Re: The 10+ year KX500 rebuild thread

Post by Luddite »

Good spot! You seem to be good (or lucky!) finding these online bargains.

I see that rear sprocket appears to be held on with three bolts. Just be aware that I think the standard mounting method on the XT is with six threaded studs and nuts with three double tab washers (presumably to minimise the possibility of stripping the threads in the aluminium hub).

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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

Luddite wrote: Sun Jan 10, 2021 2:09 pm Good spot! You seem to be good (or lucky!) finding these online bargains.

I see that rear sprocket appears to be held on with three bolts. Just be aware that I think the standard mounting method on the XT is with six threaded studs and nuts with three double tab washers (presumably to minimise the possibility of stripping the threads in the aluminium hub).

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Cheers. Three bolts are indeed missing, and the XT350 is a drum rear so these are off something else completely. The rear had an AJP caliper in the photo so I'm guessing it's a European 125 motard or similar. What's the worst that could happen bolting it to an open class 2stroke....
Last edited by derek badger on Sun Jan 10, 2021 2:55 pm, edited 1 time in total.
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Re: The 10+ year KX500 rebuild thread

Post by Luddite »

derek badger wrote: Sun Jan 10, 2021 2:19 pm What's the worst that could happen bolting it to an open class 2stroke....
:shock: :thumbup:
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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

cheb wrote: Sun Jan 10, 2021 2:05 pm Captive spacers for the win. Maybe not the win, but a lot less cursing when putting the wheel back in.
Just need to tap up a mate with a lathe...😉👍
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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

New airfilter pod arrived.

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As did a front spindle, I found some spacers I had in a drawer. Not sure if they'll be usefull or not yet.

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Just realsied I've lost the ball bearing that sits at the end of the clutch push rod. I'm off to try and find one from Fowlers or CMSNL.

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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

The wheels arrived today. As suspected they look to be off a 125. After some googling I think they were on a Motorhispania Arena 125 https://bikez.com/motorcycles/motorhisp ... d_2006.php as the disk pattern and the rim sizes match.

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The front has a 100/80-17 tyre and the rear a 130/70-17. Not wide, but it should be okay and I want to keep it fairly 'period' looking. I think fat tyres, USD forks and a 320mm disk would look out of place. I can get Pirelli Rosso 2's in this size.

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Re: The 10+ year KX500 rebuild thread

Post by derek badger »

From disk is 260mm, again this should be fine for what I'm doing. Just need a suitable calliper and mounting place, I'm thinking this twin opposing piston Brembo might do, it's the rear off a 900SS Ducati. Again it looks like period and not overkill.

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I need to find a rear one with a 20mm axle hanger and use the existing torque rod.