The 10+ year KX500 rebuild thread

[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.

[Potter]

There is definitely a knack to bump starting a 500cc single, I've never been able to do it properly even though I've had many instructions on how to do it. I know old men that make it look easy, but I'm stronger and fitter and I can't do it.

I can kick start bikes well, I've been doing it since I was a kid and this is also a knack, I know people that haven't had that education and they literally can't kick over my 500 at all, whereas I can usually get it first time, although if it doesn't want to go then you quickly get a sweat on.

[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...

[Skub]

Salty enough for 15 years ago.

[KungFooBob]

I remember buying woodruff keys almost weekly when I commuted on a string of 100cc shitters in my late teens.

[derek badger]

Salty enough for 15 years ago.

Yea, that's what I thought. The price of NOS parts now makes me cry. It's been a heavy investment this project, but as you mentioned before...it's been spread out over a long period of time!

The other tyre should arrive tomorrow, I'll take them to be fitted Friday if my mechanic is about.

Another new coil arrives tomorrow after the multimeter showed it wasn't in spec. Then I'll check the stator readings, it's new and unused...but at least 10 years old. Then that's all the ignition replaced, if it still won't start I'll look at the fuel system again as compression certainly isn't an issue.

[derek badger]

Horn and button, speedo, kill switch and fusebox all arrived and put with the other wiring bits. 'Daytime' MOT to start, then I might look at basic lights. I've got 4 x 3.7v NiCd cells out of a head torch that might be of use wired in series. A generic reg rec might be another option to convert the AC lighting coil output. I'm getting ahead of myself though, but it's cathartic to buy parts during lockdown...

[derek badger]

Got the tyres, tubes and rim tape fitted today.







Some more wiring tomorrow and continue to try and start it.

[Potter]

When you said rim tape I shuddered and expected to see green tape around the rims, but ISWYM.

[derek badger]

When you said rim tape I shuddered and expected to see green tape around the rims, but ISWYM.

Oh hell no, I can't stand that tat!

[GuzziPaul]

Them lime green gators look a bit manky next to the nice wheels and tyres.

[derek badger]

Them lime green gators look a bit manky next to the nice wheels and tyres.

It's just storage dust, they were brand new when fitted. The whole thing will get a good wash soon.