The 10+ year KX500 rebuild thread

[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

[Potter]

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

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

On first glance that doesn't look bad, I don't know what kind of value for money that represents but I know how much it costs to do a resto on other bikes and £10k is a cheap job on many, especially if you count labour or if you have to farm much of it out to specialists.

[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.

[lostboy]

I can't be the only one that is assuming that every time there's a post on here it will be of you in shorts and flip flops, helmetless, tearing up and down your road pissing off the neighbours with a cloud of two stroke gases!

Top work.

[derek badger]

I can't be the only one that is assuming that every time there's a post on here it will be of you in shorts and flip flops, helmetless, tearing up and down your road pissing off the neighbours with a cloud of two stroke gases!

Top work.

It stops being a project if you finish it...

Just making a mount for a CRF sidestand then I'll be concentrating on finishing the rollers. Need to MOT the little CG125 also, but that can wait.

3 kids under 9yrs mean there is always something that needs fixing round the house, and with the schools out the wife and I have no spare time for much else besides stopping them killing each other at the minute.

[Bigyin]

I can't be the only one that is assuming that every time there's a post on here it will be of you in shorts and flip flops, helmetless, tearing up and down your road pissing off the neighbours with a cloud of two stroke gases!

Top work.

How long exactly have you known the Badger

The day that happens the sound of Boris bullshit will be drowned out by the clang of all the jaws dropping that its actually finished

[Taipan]

In case you wanted a bit of inspiration...

[Liamblack1987]

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.

Hi Derek

I have the same letter from kawasaki with a kx I have just purchased. Have you applied for logbook yet? Did you have to contact the nova registration or did you just do mot and full the v55/5

Thanks Liam

[Count Steer]

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.

Hi Derek

I have the same letter from kawasaki with a kx I have just purchased. Have you applied for logbook yet? Did you have to contact the nova registration or did you just do mot and full the v55/5

Thanks Liam

He's a bit elusive is Mr Badger, worth tagging @derek badger to see if he's still communicado.