The 10+ year KX500 rebuild thread

[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.

[Scuffmark]

What are the chances of finding a KX hub ? .... And would that have the same number of spokes ?

[Skub]

The carrier does look a bit spindly viewed side on.

I'd take a chance on it with you riding dude.

Me...not so much.

[derek badger]

What are the chances of finding a KX hub ? .... And would that have the same number of spokes ?

Doesn't have to be a hub off this model. The 85 was a drum brake so it went in the bin as the wheel was bent.

[derek badger]

New clutch assembly fitted and torqued up. Cleaned up the mating surfaces and ordered a gasket set.

[demographic]

What are the chances of finding a KX hub ? .... And would that have the same number of spokes ?

There's a bloke with an offroad bike forum (KX Guru) in the US, calls himself Sandblaster and from memory he has a motocross breakers in Eugene Oregon.

I bought a KX500 rear subframe off him a while ago and he's pretty damn good at getting KX bits.
In fact the Ebay.com site and the US is generally just way better for turning KX 500 bits up.

[derek badger]

What are the chances of finding a KX hub ? .... And would that have the same number of spokes ?

There's a bloke with an offroad bike forum (KX Guru) in the US, calls himself Sandblaster and from memory he has a motocross breakers in Eugene Oregon.

I bought a KX500 rear subframe off him a while ago and he's pretty damn good at getting KX bits.
In fact the Ebay.com site and the US is generally just way better for turning KX 500 bits up.

Yea, very popular desert bike in So Cal, Utah etc. so spares are more abundant. Looks like I can get 35 OD, 20 ID bearings so will go with the wheels I've got on there to start with. Found a firm that can do a custom sprocket too, but first I need to get the engine running....

[cheb]

Talon were excellent when I needed a special sprocket for the TDR.

[derek badger]

So it was a good guess that it was a European 125 motard the wheels came off, turns out they are common on a range of bikes - Peugeot XPS125, Motorhispania Arena and Duna 125, Derbi Sanda and a couple of others. I managed to find the dims for the sprocket to get a 520 one machined up and Cheb has kindly offered to knock up some top hats for the axle sliders to allow me to fit a 15mm axle and work out the alignment for the chain and brake hanger and get the dimensions for the required spacers so I'll be using the wheel.





Gasket set is in the post. When that arrives the next steps are gearbox oil, coolant, reconnecting the wiring for the coil/CDI/kill switch and checking the points gap...and trying to get a spark. Oh, and I've ordered some 10mm ally plate for the front brake adaptor, cardboard template first of course.

[demographic]

Original rear axle diameter for the 85-87 on this thread.
http://www.oem-cycle.com/forum/viewtopic.php?f=49&t=593


And this picture with dims. I can see it but I'm a member so if you can't I'll copy it instead.

[derek badger]

Cheers mate, I've got the original, but the bearings on the new wheels are 15mm ID so I need to sleeve down the adjusters from 20 to allow a narrower spindle.

[demographic]

Cheers mate, I've got the original, but the bearings on the new wheels are 15mm ID so I need to sleeve down the adjusters from 20 to allow a narrower spindle.

Yeah, I knew yoh have different wheels for it now but wasn't sure you had the original.

How wide is the new rear wheel BTW?
You might have to offset the rim slightly if its too wide pr you can end up with the chain rubbing the tyre side.

[derek badger]

It's narrow, 130 rear section tyre.

[demographic]

When I first got my KX it had a 3.5" rear Morad with Trailwing tyres if I remember right.
Anyway, the chain was fine with that.

[derek badger]

Gasket set and wheel bearings arrived. I've had too many beers to be fucking about in the workshop tonight though.





Bolt it back up and get some gearbox oil in it tomorrow.

[Potter]

I'd take a chance on it with you riding dude.

Aluminium has a half life of about 700k years, it will have disintegrated before he's finished it

[derek badger]

I'd take a chance on it with you riding dude.

Aluminium has a half life of about 700k years, it will have disintegrated before he's finished it

Fluids going in now...

[Taipan]

Can you film it starting up! I need to witness this momentous and historic occasion and get a ring-a-ding-ding fix to boot!

[derek badger]

Cleaned up the old connectors and used new jap spec m/c ones on the stator leads. Put a temp kill switch in there too.