The 10+ year KX500 rebuild thread

[demographic]

You'll likely have seen this but just in case, its a what fits what year parts interchangeably err...thing.

You can scroll a bloody long way over to the right to see what parts from what bikes fit what.
http://www.oem-cycle.com/KAWASAKIKX500BIKEID.shtml

[cheb]

Have you a links to the decompressor mods? I did have them but they've been lost somewhere down the mine.

[demographic]

Have you a links to the decompressor mods? I did have them but they've been lost somewhere down the mine.

I've got a load of pics on an old memory stick somewhere here but this thread covers what it looks like on the 1288 E1 and E2 head which I think is the same from 88-04 bikes. Or at the very least mine (90) to 04.
https://www.kxriders.com/forums/index.p ... 956.0.html
The 86 head is different and from whatI saw can have the decomp valve fitted through one of the bolts for the water pipe connector on the head.
I put a link up a page or two back on this thread for that one.

More about it here.
http://oem-cycle.com/forum/viewtopic.php?t=184

There's another way to do it which has to drill through the cylinder and personally I'd avoid that one like the plague.

[demographic]

Got one of these today... it seems that the LED tail light bulb I have manages OK with 18 volts, besides if it didn't I would just use the lorry versions rated for 24 volts instead.
My LED headlight bulb does too which only leaves the horn and indicators to sort, can't be rocket science can it?
I already have a Hitachi drill handle part that does the same but the De-Walt one is much neater.


With a dewalt battery.


Years ago I made up a tiny battery box that went behind a sidepanel but the battery was pretty gash.
Now I'll just put it in one of those tailpack things that live just behind the seat.
Not exactly pretty but with a four (US) gallon tank the bike isn't exactly pretty anyway.

[derek badger]

Knocked up a make shift bracket to level and hold the laser now the plastic spacers are fitted and the wheel is central in the swingarm. Chain alignment is almost perfect but until I have the correct rear sprocket I won't be 100% sure.

[weeksy]

Nice work there !

[derek badger]

Both bushes on the linkage are are fucked, as is the top shock bush. All balls racing will probably stock them, but I might look into a shock from another bike. The '86 KX 250 is the same at about 415mm eye to eye but it's as hard to come by as the one of this model.



I replaced the swingarm bearings when the frame was stripped at the start of this project, might have down the rocker ones too as they have zero play in them.

[derek badger]

Started stripping the shock, it still had gas in it and fluid. The fluid was fucking rank, actually made me gag. I've ordered a new linkage bush/bearing kit and a shock seal kit. I'll be stripping it down further and checking the remote reservoir bladder out while it's apart.



Rang Talon and placed the order for the sprocket, 12 weeks lead time. Ho-hum. Plenty to get on with, front-wheel spacers next then I'll have the dimensions for all 4 to get them turned up.

[derek badger]

Oh, and Talon Engineering had that pattern with a 520 pitch on file. Turns out some Gas Gas models run it. Again, a European manufacturer.

[derek badger]

And while I'm here drinking cider and mulling things over, having more than one work bench is fucking brilliant. The project really is gathering momentum due to the fact I have much better working conditions and facilities than I've ever had.

[derek badger]

Oh, and Talon Engineering had that pattern with a 520 pitch on file. Turns out some Gas Gas models run it. Again, a European manufacturer.

I may have missed a comment along these lines, but maybe have a batch made up and flog them on ebay at a margin to make yours free?
I'd be keeping a couple spare anyway.

I doubt I'd be able to compete with the likes of Talon, I've been quoted 40 odd quid + VAT and shipping. They had a part number for this item, so it's something they would normally have on the shelf or have made before.

The lead time is only because there are no blanks at all in this country. Every manufacturer I contacted is waiting for stock.

[derek badger]

Linkage bearings and bushes arrived this morning. Need to get the shock finished and reassemble the suspension. Back brake hanger and master cylinder mount to fabricate, then sort a pedal out and that's the rear end done. Front requires wheel alignment and caliper mount, then that's all the running gear sorted.

[derek badger]

Shim stack and seal head finally out of the shock tube. That was a bit of a bugger but YouTube videos helped.



Ever wondered what inside a 1980s remote reservoir shock...

[derek badger]

Email from the French firm the CDI is coming from. Order status changed from 'awaiting parts' to 'order being prepared'.

[derek badger]

Seal head arrived, 2.5w shock oil should be here tomorrow.

I took the uni-trak rocker out to paint it and I hadn't change the needle rollers. The All Balls kit came with these parts so it seemed silly not to do it. I managed to drift the bearings out so far with a socket and the vice jaws but the vice isn't deep enough to get a larger socket over the other end to push them through. I know this as I wound it open as far as I could..so far that the split pin snapped and the vice now needs stripping down to be repaired. A die grinder and a punch are slowly getting the remains of the mangled needle rollers out but they're tough as fuck and I need to go gently.

[derek badger]

Replaced the pin in the vice and mounted it back on the bench. Got the bastard needle rollers out in the end with no damage to the main part, got to love a die grinder... marvelous tools.



Dog bone bearings and seals replaced. Wound the ride height adjuster in for my short legs.



Started sprucing up a couple of bits with rattle cans, but I've run out of time for today.

[derek badger]

I'm shopping for tyres now.

3.0 front rim, 3.5 rear. OEM fitment is 100/80-17 and 130/70-17, it's currently got Conti Twist SMs on there, which look fucking awful. I can get much more choice if go for 110/70-17 and 140/70/-17. Chain clearance shouldn't be an issue.

Any thoughts from the masses?

Current short list is Dunlop GPR-300's or Pirelli Diablo Rosso 2's (available in both OEM size and 100/140 width), or the budget Pirelli Angel City's.

[weeksy]

I'm shocked and massively Impressed.

Tbh when we met and talked on the way to Pembrey I never for a second thought you had something like this in you. You're a bit of a dark horse sir!

[derek badger]

Shock and linkage bushes all replaced and reassembled.





And as this was originally called 'Project Scumpy' by my mate Richard I thought it only fitting to wrap the remote reservoir with a cider can.

[cheb]

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