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Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 14, 2021 2:30 pm
by Scuffmark
What are the chances of finding a KX hub ? .... And would that have the same number of spokes ?
Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 14, 2021 2:38 pm
by Skub
The carrier does look a bit spindly viewed side on.
I'd take a chance on it with you riding dude.
Me...not so much.

Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 14, 2021 2:46 pm
by derek badger
Scuffmark wrote: Thu Jan 14, 2021 2:30 pm
What are the chances of finding a KX hub ? .... And would that have the same number of spokes ?
Doesn't have to be a hub off this model. The 85 was a drum brake so it went in the bin as the wheel was bent.
Re: The 10+ year KX500 rebuild thread
Posted: Sat Jan 16, 2021 2:25 pm
by derek badger
New clutch assembly fitted and torqued up. Cleaned up the mating surfaces and ordered a gasket set.

Re: The 10+ year KX500 rebuild thread
Posted: Sat Jan 16, 2021 3:31 pm
by demographic
Scuffmark wrote: Thu Jan 14, 2021 2:30 pm
What are the chances of finding a KX hub ? .... And would that have the same number of spokes ?
There's a bloke with an offroad bike forum (KX Guru) in the US, calls himself Sandblaster and from memory he has a motocross breakers in Eugene Oregon.
I bought a KX500 rear subframe off him a while ago and he's pretty damn good at getting KX bits.
In fact the Ebay.com site and the US is generally just way better for turning KX 500 bits up.
Re: The 10+ year KX500 rebuild thread
Posted: Sat Jan 16, 2021 3:54 pm
by derek badger
demographic wrote: Sat Jan 16, 2021 3:31 pm
Scuffmark wrote: Thu Jan 14, 2021 2:30 pm
What are the chances of finding a KX hub ? .... And would that have the same number of spokes ?
There's a bloke with an offroad bike forum (KX Guru) in the US, calls himself Sandblaster and from memory he has a motocross breakers in Eugene Oregon.
I bought a KX500 rear subframe off him a while ago and he's pretty damn good at getting KX bits.
In fact the Ebay.com site and the US is generally just way better for turning KX 500 bits up.
Yea, very popular desert bike in So Cal, Utah etc. so spares are more abundant. Looks like I can get 35 OD, 20 ID bearings so will go with the wheels I've got on there to start with. Found a firm that can do a custom sprocket too, but first I need to get the engine running....

Re: The 10+ year KX500 rebuild thread
Posted: Sat Jan 16, 2021 4:50 pm
by cheb
Talon were excellent when I needed a special sprocket for the TDR.
Re: The 10+ year KX500 rebuild thread
Posted: Mon Jan 18, 2021 5:47 pm
by derek badger
So it was a good guess that it was a European 125 motard the wheels came off, turns out they are common on a range of bikes - Peugeot XPS125, Motorhispania Arena and Duna 125, Derbi Sanda and a couple of others. I managed to find the dims for the sprocket to get a 520 one machined up and Cheb has kindly offered to knock up some top hats for the axle sliders to allow me to fit a 15mm axle and work out the alignment for the chain and brake hanger and get the dimensions for the required spacers so I'll be using the wheel.
Gasket set is in the post. When that arrives the next steps are gearbox oil, coolant, reconnecting the wiring for the coil/CDI/kill switch and checking the points gap...and trying to get a spark. Oh, and I've ordered some 10mm ally plate for the front brake adaptor, cardboard template first of course.
Re: The 10+ year KX500 rebuild thread
Posted: Mon Jan 18, 2021 6:16 pm
by demographic
Original rear axle diameter for the 85-87 on this thread.
http://www.oem-cycle.com/forum/viewtopic.php?f=49&t=593
And this picture with dims. I can see it but I'm a member so if you can't I'll copy it instead.

Re: The 10+ year KX500 rebuild thread
Posted: Mon Jan 18, 2021 7:06 pm
by derek badger
Cheers mate, I've got the original, but the bearings on the new wheels are 15mm ID so I need to sleeve down the adjusters from 20 to allow a narrower spindle.
Re: The 10+ year KX500 rebuild thread
Posted: Mon Jan 18, 2021 7:16 pm
by demographic
derek badger wrote: Mon Jan 18, 2021 7:06 pm
Cheers mate, I've got the original, but the bearings on the new wheels are 15mm ID so I need to sleeve down the adjusters from 20 to allow a narrower spindle.
Yeah, I knew yoh have different wheels for it now but wasn't sure you had the original.
How wide is the new rear wheel BTW?
You might have to offset the rim slightly if its too wide pr you can end up with the chain rubbing the tyre side.
Re: The 10+ year KX500 rebuild thread
Posted: Mon Jan 18, 2021 7:27 pm
by derek badger
It's narrow, 130 rear section tyre.

Re: The 10+ year KX500 rebuild thread
Posted: Mon Jan 18, 2021 8:35 pm
by demographic
When I first got my KX it had a 3.5" rear Morad with Trailwing tyres if I remember right.
Anyway, the chain was fine with that.
Re: The 10+ year KX500 rebuild thread
Posted: Tue Jan 19, 2021 7:19 pm
by derek badger
Gasket set and wheel bearings arrived. I've had too many beers to be fucking about in the workshop tonight though.
Bolt it back up and get some gearbox oil in it tomorrow.
Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 21, 2021 1:22 pm
by derek badger
Potter wrote: Wed Jan 20, 2021 1:12 pm
Skub wrote: Thu Jan 14, 2021 2:38 pm
I'd take a chance on it with you riding dude.
Aluminium has a half life of about 700k years, it will have disintegrated before he's finished it
Fluids going in now...

Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 21, 2021 1:51 pm
by Taipan
Can you film it starting up! I need to witness this momentous and historic occasion and get a ring-a-ding-ding fix to boot!

Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 21, 2021 3:33 pm
by derek badger
Cleaned up the old connectors and used new jap spec m/c ones on the stator leads. Put a temp kill switch in there too.

Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 21, 2021 3:33 pm
by derek badger
We have a spark...
Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 21, 2021 4:27 pm
by Skub
Yay!
All those sparks have been waiting over a decade just to get out,like a tadpole from a bustin' full ballbag.
Re: The 10+ year KX500 rebuild thread
Posted: Thu Jan 21, 2021 5:03 pm
by derek badger
Skub wrote: Thu Jan 21, 2021 4:27 pm
Yay!
All those sparks have been waiting over a decade just to get out,like a tadpole from a bustin' full ballbag.
That's a mental image I really am going to have to power-drink though to remove...