The 10+ year KX500 rebuild thread

[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.

[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.

[derek badger]

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

[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.

[cheb]

That's good. I found the DVLA to be efficient when I had to register the TDR and then the DTR,

[Asian Boss]

Don't worry about all that paperwork bollocks, get it up on t'back wheel.

[derek badger]

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.

[cheb]

It was all by post for me, all documents and photos on paper with some money.

[derek badger]

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

Stuck a drunken bid in on these and won them!






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.

[Skub]

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

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.

[cheb]

Captive spacers for the win. Maybe not the win, but a lot less cursing when putting the wheel back in.

[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).

[derek badger]

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).

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....

[Luddite]

What's the worst that could happen bolting it to an open class 2stroke....

[derek badger]

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...

[derek badger]

New airfilter pod arrived.





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



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.

[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.





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.

[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.





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

[derek badger]

The rims and spokes look of decent quality, I'm a little bit concerned about the rear hub though. The sprocket doesn't seem to be bolted to that much 'meat' as it were. Fine for a 12bhp bike, but 50bhp? Hmmm, what do you lot think? As I say the rims are Morad jobs so I could always get the rear relaced to a different hub. Dunno. I'll see if I can get a custom 520 sprocket with that bolt pattern and then at least get it MOT'd.

[derek badger]

Anyway, the spoked wheels certainly look loads better than cast ones when they are on the bike.