Maintenance & Technical > KX500 Original

Lack of use/what to do.

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Danger4u2:
It's a good idea to check the copper washer between the exhaust pipe and the cylinder.  
There's 2 o-rings on the pipe that seal the cylinder to the pipe.
When removing the pipe, after removing the tension springs
I take the 2 nuts off on the upper mounts.  
On the lower mount I remove the bolt and leave the
rubber isolator on the pipe so the pipe can be twisted and
moved forward.  It's very easy to bash the center mount on
the radiator, install a small piece of cardboard for protection.
Don't ask why I know to do that.
All the replaceable parts work in harmony. Wear on any one of
these parts make the others break down fast.  When installing the
pipe it needs to hang in a neutral position.  Any stress on the rubber
mounts will kill the life of the other 2.  Lock tight is your friend
on the 3 nuts and 3 bolts used on the rubber mounts.
My springs, mounts, copper gasket and o-rings were in useable condition.
I rotated the o-rings in their grove and smeared a very thin coat of
copper anti-size on the rings to aid the insertion into the cylinder.
The last picture shows how my pipe does not fit flush on the
copper washer, the o-rings seal, might be part of having an
after market pipe.  I thought about adding a second copper washer.

Danger4u2:
The swing arm pivot bolt is over looked on most bikes.
It's a long bolt that runs through the frame, swing arm
and on most dirt bikes, the engine.  Over time dirt and water
will rust it in place. Or it will develop wear groves that hang
up on the edges of the holes it has to travel through to be removed.
Raise the bike to get the back wheel off the ground. 
Insert something under the wheel that just fits so the wheel
won't drop when you remove the bolt.
Worst case scenario remove the nut and spin the bolt with an impact
gun while your friend taps the other end with a long punch and hammer.
Clean and then sand the bolt with fine grained sand paper.
Scoop some water proof grease with your punch and apply
it to the holes of the swing arm, frame and engine.
Smear the first half of the bolt (thread  side) with grease
so you have a clean end to hold onto as you insert it into the frame hole.
Tap lightly to get it started, grease the rest of the bolt.  You may have to
wiggle the backwheel/swing arm to get it to go. On the k5 it calls for
58 foot pounds of torque.
On the kx500 you need to remove the brake peddle to access the nut.
That's a good  time to clean and grease the brake peddle pivot and bushing.
There is a recessed groove in the bushing of the peddle, make sure
to fill it with water proof grease. Here again I'm a Bel-Ray fan.

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