Maintenance & Technical > KX500 Original

1985 KX500 questions

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Abbott:
Hey everyone. I just picked up an '85 KX500 from a friend who just dumped a ton of money into this thing. He recoated the cylinder, replaced the pistons and rings, new crank main bearings and seals, transmission gears, transmission forks and so on. he got it all back together and the bike would fire up no problem but the bike will not shift. Thinking he got the transmission forks in the wrong grooves or something. I won't know until I get here and am not too concerned with that.

I am going to purchase a manual soon for this but in the meanwhile, I wanted to pick some brains. Do the case halves and engine covers have their own gaskets (and where can I find these?) or does everyone use gasket maker to seal up the lower end of the motor?

sandblaster:
Never done a 85, only back to 86.
I did find a gasket kit..

http://www.ebay.com/itm/Winderosa-808473-Complete-Gasket-Set-Kawasaki-Dirtbike-For-Kx500-1985-/361412154250?hash=item5425d7d38a:g:2woAAOSwl9BWJSI0&vxp=mtr

Abbott:
thanks for the reply. i'll probably end up ordering a kit. it looks like the guy who was in there before me used some kind of gasket maker. I wasn't sure if the gaskets provided required "shimming" for the motor when being re-assembled.

sandblaster:
Ok, I went to partzilla to look at a exploded diagram of your cases.
There is no main case gasket which is consistent with the 86-04 engines.
You will need a case sealant like Yamabond or similar.

http://www.partzilla.com/parts/search/Kawasaki/Motorcycle/1985/KX500-B1+KX500/CRANKCASE/parts.html

Before you do any assembly, wait for your service manual...

For a nice starter I have condensed a build on this site down to it's most informative parts here:

http://www.oem-cycle.com/forum/viewtopic.php?f=41&t=824

Basically I removed a lot of the banter (Which is fun reading) And kept just the info..

Same thing here;

http://www.oem-cycle.com/forum/viewtopic.php?f=41&t=878

Post pics when you can

Abbott:
Thanks Sandman. really valuable information there! i'll post pictures when I can. looks like I cannot upload them directly here? I'm guessing I have to use photo bucket or some sort of image uploading site.

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