Maintenance & Technical > KX500 Original

1985 KX500 questions

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sandblaster:
Post a pic of your resonator box.

Abbott:
The cracked box



Was able to get a lot done yesterday...
-made the new sleeve from 6061 aluminum for the kick start assembly. I glued the broken pieces together to get a couple rough measurements. just need to machine the engine cover flat so I can have some guys at work weld it together. made a tool that will guide through the kick start shaft seal counter bore so I know the new sleeve will stay nice and straight.

Abbott:
Got the bike apart and motor out of the frame. A lot of work to do and not impressed at all with what the previous owner has done so far.

-tail section cross member needs to be re-welded
-exhaust mount broken (header), needs to be re-welded
-master link was on backwards and almost ground down to nothing
-completely missing the output shaft (front sprocket) retaining nut.
-one motor mount was stripped really bad (easy replacement)
-cylinder looks pretty beat up around the ports. it definitely needs to be stripped and replated
-none of the washers were beaten over against the nuts for any of the gears
-the clutch nut, primary gear nut and flywheel nut were hardly tight...clearly not to spec.
-the flywheel woodruff key was sheared
-piston is still in good shape...need to clean it up and file some rough edges but I can use it
-couple of transmission dogs look a little rounded to me (i'll get pictures up another time and get your opinions)
-still a lot to go through and inspect once I get the manual in. she's going to need some work!!

Oh, and the last picture I just thought was cool because the piston is bigger than my fist...and I don't have small hands LOL

tobys 2 strokes:
I would dump the resonator they are fine with out it.
I think I have a good clutch cover for a 85 if your repair proves to be to much of a pain.

Abbott:
Hey Toby. Thank for letting me know! hoping to mill out the engine cover today and then take it to the welding department. If it doesn't work, i'll be sure to let you know.

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