The 10+ year KX500 rebuild thread

[derek badger]

I've just remembered I need to do the other spacer for you.

I'm just working out the front axle spacers at the minute. I'll drop you a PM with the final dims for all four, but no rush as I've got plenty to do still. Cheers mate.

[cheb]

No worries.

[derek badger]

Today I removed the decals I put on years back with the exception of the the swing arm and a comedy one I quite like. I've got some period repo ones coming on the post and I found a set of rad shroud ones in the back of the shed that I might be able to do something with.









The first of the tyres turned up as did a pair of new Michelin inner tubes.



I need to come up with a solution for this monstrosity. It's the mud flap that attaches to the suspension linkage. Several of the mounts are split and it's ugly as fuck. Once again it's a discontinued part, so I either need to find something else to use or bodge it with penny washers.





Parts ready to fit and the various schematics/diagrams I've been working from. A white board and a pin board have been very useful during the build. CDI is with DHL and should be with me next week and sprocket is ordered. Don't think there is anything else major outstanding at the minute, need to get a kill switch, pushbike speedo and horn but I've got all the other wiring materials to make the small loom. Might leave the lights until after the first MOT, but if things progress smoothly I'll take a look at fitting a dipped/high, rear and brake light.



I think I've settled on the brake set up. Sliding 2-pot at the front, chose one with a flat mounting plate that I can take the pins off and attach to the bracket I fabricate. 2 pot opposing Brembo for the rear.







Front axle spacers now mocked up in plastic pipe so both wheels are central in the forks/swing arm and the dims have been given to Cheb as he's kindly offered to turn them up on his lathe. Top bloke.

[derek badger]

CDI unit arrived and is well made with the correct colour wires and terminal genders. Fitted it and it produces a decent spark, however I couldn't get it to fire more than a couple of times and then it wouldn't fire at all. Plug was wet so I suspect it was flooded, turn it over a few times by hand with the plug out and leave it until Saturday.

Same again on Saturday, and I give up as my right calf is fucking killing me. Sunday I take the carb off as I notice there is a puddle of petrol on the floor. I then take the intake boot off and the reed block. Fucking hell, I forgot how big the 6 petal Boysen reeds and the intake/transfer ports are!



Peering in with a torch I can hear the sound of premix sloshing about and have a think about how to drain the crankcases and remember I've got a Mityvac in one of the drawers. About 200ml came out! Looks like the needle valve on the carb isn't seating or the float is sticking so I've got the carb (and a spare one) in bits and will try and get it rebuilt today/tomorrow.

[derek badger]

Axle spacers arrived in the post from Cheb today and are a perfect fit. Once the front tyre arrives (stuck in Holland for some reason) and I've got them both fitted it'll be much easier to move about.

[cheb]

That's good to know, I forgot to send you the tracking number at the weekend.

[derek badger]

Replaced the valve and tweaked the float height. Seems okay now.

[derek badger]

Replaced the valve and tweaked the float height. Seems okay now.

So does it run?

I ran out of patience and time last night when it lost spark. I'll be cleaning all earth points, trying a new HT lead and checking the stator again today.

[KungFooBob]

Always, always, always try a new plug first.

Several years racing a two stroke taught me that.

[derek badger]

Always, always, always try a new plug first.

Several years racing a two stroke taught me that.

I've got 2 new plugs. A BR8EG and a BR8EG, both have been in boxes for 10 years unused.

[derek badger]

Always, always, always try a new plug first.

Several years racing a two stroke taught me that.

I've got 2 new plugs. A BR8EG and a BR8EG, both have been in boxes for 10 years unused.

Always, always check the wiring is connected correctly after you disconnect things when you've been drinking cider. The 2 x wires from the CDI to the coil and earth are B and BW. The two wires from the coil/kill switch are B and B...I've now marked one of them with white tape.

Still can't fucking start the beast though. It fired a couple of times but by fuck it's hard work even in Moto-X boots. I've got Thu & Fri off work so I'll make sure I have me weetabix those days.

[cheb]

The sprocket, have you got anything close to you what you need that could be drilled to suit?

[derek badger]

The sprocket, have you got anything close to you what you need that could be drilled to suit?

To bump start it?

[demographic]

Got to admit that I've never found mine right easy to bump start.
Long travel suspension, high seat and a fair dollop of compression made for hard work even on tarmac.

Then after a while the kickstart knuckle wore so it overrotated and my foot would sometimes slip off.

Upto that point it was usually first or second kick but thats a whilemumbleswerveages ago.
I keep eying up the decomp conversion cos MX boots are bloody shite for normal use. I don't mind wearing workboot type of things but can't be done with stomping about like Robocop everytime I want to ride a bike.

[derek badger]

I lived on top of a big hill and once tried to bump my YZ465 all the way down. It didn't start and I had to push the fucker all the way back up...

[cheb]

Not for bump starting, for checking if the gears etc work or a gentle test riding once you get it running.

Is it road registered?

[demographic]

Oh and if you do have a go at bumping it, first make sure the clutch can free up or you could end up with some nasty skidmarks when it fires up.

Or so I've read anyway

[derek badger]

Not for bump starting, for checking if the gears etc work or a gentle test riding once you get it running.

Is it road registered?

Gears all select okay, it's had a full rebuild and I trust my mechanic that he'd have noticed any broken bits when he did it. It isn't registered yet, but will be. MOT via van transport is the plan. I've got not rear sprockets that would work so I'll wait for Talon to deliver.

[cheb]

OK, that would have been my next thing, to get it to the tester sooner.

[derek badger]

Christ. I just found the receipt for the rebuild from 15 years ago...