Maintenance & Technical > KX500 Original

1998 KX500 | OEM Spec Build

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Ims Roll:
No reason to fight the chain and swing arm guard when you are adjusting the rear shock... I would mount it with the screw facing the brake side of the bike. (I know it is an old post but might as well)

manco:

--- Quote from: Ims Roll on May 05, 2017, 03:54:37 AM ---No reason to fight the chain and swing arm guard when you are adjusting the rear shock... I would mount it with the screw facing the brake side of the bike. (I know it is an old post but might as well)

--- End quote ---
I am getting around to continuing the build and am about to pull the swingarm and rear linkage for new bearing installation. I will probably switch the position of that piece when I reassemble.

manco:

--- Quote from: 450 OX on March 13, 2017, 08:23:15 AM ---looking good so far! question where did you purchase the silicone coolant hoses? Id like to get a set for myself.

--- End quote ---
I got them off fleabay with the radiators. Some pieces didn't fit for crap. My radiators didn't fit for crap either so maybe I just got some crap all around. The above pictures may not show it but I ended up putting an OEM hose in from the water pump up to the radiators. That silicone hose was the worst. One of the other silicon hoses also fit bad but did work. I have an OEM on hand to replace it next time I pull the cylinder. Unless colored silicone looks is a big issue my advice is to just get OEM hoses. They are much more durable and fit better.

manco:
I have actually had this build together for awhile now. One thing I wanted to point out was I swapped the OEM Kawasaki brakes to 2001 Honda CR125 brakes for more stopping power or so the myth goes. The calipers and master cylinders fit fine. I did cut down the threads on the rear brake caliper lever mount to fit better. The front and rear brake lines from the Honda fit fine but I ran into issues with the Honda front brake line. The CR125 line fit but when the fork compressed the hose got too close to the disk and it got cut. I noticed it luckily before it was an issue. The way the hose mounts on the CR125 forks and fork guards is different then the Kawasaki so the hose and style of routing won't work with KX500 forks and guards. Below are pics of the bike last year when it was fresh out of the shop with the the bad front brake hose routing. Again don't try this or you will eventually slice through the front brake line.

manco:
Here are pics of the current state of the build. Note the standard OEM front brake line and routing now in place. I am finally getting around to getting the rear suspension bearings replaced. I also have an aftermarket white number plate that was as close to stock as I could find as the OEM plate is no longer available. I have a green OEM front fender to put on and am waiting for a green OEM rear fender and an OEM white rear brake guard to arrive. Unfortunately the OEM rear brake guard and fender are stuck in parts ordering hell. They are part of an order with .40 OEM fork springs. The fork springs were back ordered for over a month until I bugged the supplier who finally responded they were no longer available. Now I am waiting for OEM .39 springs which are also back ordered for another 3-4 weeks but luckily are still available. After spending so much time on suspension-less bicycles I am a really light rider when it comes to style so the .41 springs are stupid stiff for me. They jack the front end of the bike up too much anyway when I am on it so I am looking forward to some lighter springs.

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