The 10+ year KX500 rebuild thread

[weeksy]

out of interest, why are yours flat and more modern bikes ridged in the middle ?

[derek badger]

out of interest, why are yours flat and more modern bikes ridged in the middle ?

Mine should be ridged, but they aren't avaialble so I made these out of thicker flat with countersunk bolts.

[weeksy]

out of interest, why are yours flat and more modern bikes ridged in the middle ?

Mine should be ridged, but they aren't avaialble so I made these out of thicker flat with countersunk bolts.

Yes I get that. But that's not what I was asking lol

Why do the standard ones have ridges ?

[Le_Fromage_Grande]

out of interest, why are yours flat and more modern bikes ridged in the middle ?

Mine should be ridged, but they aren't avaialble so I made these out of thicker flat with countersunk bolts.

Yes I get that. But that's not what I was asking lol

Why do the standard ones have ridges ?

To keep the chain in the middle of the slider if it has too much slack

[weeksy]

Mine should be ridged, but they aren't avaialble so I made these out of thicker flat with countersunk bolts.

Yes I get that. But that's not what I was asking lol

Why do the standard ones have ridges ?

To keep the chain in the middle of the slider if it has too much slack

Will not having ridges cause him potential issues?

[derek badger]

Yes I get that. But that's not what I was asking lol

Why do the standard ones have ridges ?

To keep the chain in the middle of the slider if it has too much slack

Will not having ridges cause him potential issues?

I very much doubt it.

[derek badger]

The sprocket guard is the same on the 85-95 cases so I picked a billet one up on eBay. One of the previous owners had snapped off the bottom lug so it meant some epoxy and a couple of filed down spacers to bring it back in line with the top mount.





Next is the rear chain guide, I'll probably just make something out of alluminium plate and some of the acetel bar that I used for the swingarm sliders.



And finally a couple of shots of it up on the lift looking menacing.





Now it's got a front brake I'm going to spend my time sorting out the roller starter (in the workshop thread) and then I can at least get the engine spinning for more than 5 seconds using the kick start.

[demographic]

Could your flywheel have lost its magnetism?
I have a 93 flywheel you can borrow if it fits?
No idea if it will but I think the crank is the same from about 84-04 so I guess the taper is the same on the end anyway.
Give me some time and I'll have a PWK 39 carb I can lend you to try on it as well, just so you know what it isnt IYSWIM.

[derek badger]

Could your flywheel have lost its magnetism?
I have a 93 flywheel you can borrow if it fits?
No idea if it will but I think the crank is the same from about 84-04 so I guess the taper is the same on the end anyway.
Give me some time and I'll have a PWK 39 carb I can lend you to try on it as well, just so you know what it isnt IYSWIM.

Very kind offer fella.

When it was off last it certainly had a screwdriver sticking to it. The spark seems okay, I think kit just needs to clear its throat as were, and get the carb dialed in.

[ZRX61]

Now it's got a front brake I'm going to spend my time sorting out the roller starter (in the workshop thread) and then I can at least get the engine spinning for more than 5 seconds using the kick start.

I was beginning to wonder if you'd still be fit enough to start it after all this time
Just stuff an H2 750 engine in it

[demographic]

Very kind offer fella.

When it was off last it certainly had a screwdriver sticking to it. The spark seems okay, I think kit just needs to clear its throat as were, and get the carb dialed in.

No worries bud, if you need em just give me a shout.
Most of my other spares are bodyparts for an 88-2004 bike.
There's a few bits that stayed the same over the decades they were built for or even if they changed they were close enough to fit.
Kawasaki and their very long production runs are something to be thankful for.

From what I understand using a KDX 200 flywheel gives enough space for a slightly more powerful lighting coil as well. I've not tried that one mind.

[derek badger]

Mounting brackets for rear M/C done. 5mm steel with nuts welded to the rear.





I found a decent lenghth of ally rod for the torque arm and fitted a new rose joint to the frame end, the other end will be clevis fork connecting to the caliper bracket.



Heat barrier tape applied to the tank where it's close to the spanny and the rads, plus some on the rear panel where it's near the silencer.







A couple of decals arrived so I applied them too, the RHS one is a horrible compound curve so it had to be slit in a couple of places to fit.

[demographic]

Bit of a random one but I found these pics in amongst various big motocrosser info I have.
Crap pics and somewhere I'll have better versions but I thought you might like this clever detail.
Tunable crank weights for different rpm applications.
I'm pretty sure these were on a works CR500 but you'll get the idea.

My guess is Tungsten*, Brass, and plastic. All held in place by circlips.



I'm not suggesting you do it, just thought it was an interesting detail to show the guys.
*Could be steel but thats basically just standard isn't it.

[Skub]

There ya go man,get it finished and you're in the money.

https://www.ebay.co.uk/itm/124765284817 ... dKXkhSv0z4

[derek badger]

That's an '88 model and parts are easier to come by, mine will not be anywhere near a concurs rebuild. Think more along the lines of hill climb special built in a shed.

[derek badger]

There ya go man,get it finished and you're in the money.

https://www.ebay.co.uk/itm/124765284817 ... dKXkhSv0z4

https://www.ebay.co.uk/itm/373600228454 ... Sw0~pgtkv7

£5000 for an old shitter?!

[Skub]

Prices on even faintly old bikes are ker-azy. I wonder how many get close to asking price.

[Taipan]

Just in case you needed a bit of inspiration...

[demographic]

Just in case you needed a bit of inspiration...

90 model, same as mine.
Gold USD forks.

[derek badger]

Picked up a CR500 swingarm at Kempton for a tenner. I only wanted the chain guide. Had to take off a 4mm notch of the nylon with the dremmel to align it properly, but it fits.