Maintenance & Technical > KX500 Original
Chronic problems?
Zombie:
Hey all. while I was looking around on the 'net, I came across Larry's CR site, and saw some ugly pics of a blown transmission, and some other people there have had blown trannys and cracked cases and bearing cups, etc. All this got me wondering, what problems should I look for when looking at a 500? I know about the expansion chamber tab under the tank, (It happened on my 85, and my fix was ultra low-tech- hose clamp the stinger to the frame)) and to check the bottom frame rails (they were smashed on my 85, but I got new ones made.) and to make sure the suspension linkages and related parts dont have any slop in them. It seems that CR trannys arent very reliable, so, what about KXs? Any common failings besides that infuriating pipe tab? Whats likely to be the first thing to go? Any and all input would be aprecciated!!
Later!
-Z
Rick:
The first thing to go on ALL of my 500's (I buy a new one every year or two, so anything that happens is related to my riding) is the top radiator tab breaks at the 90 degree bend. On the first one in 1999, I had it fixed. However, after that first one, I just let it stay broken. To my surprise, because the radiator has 3 mounts, the other two mounts, plus the top hose connecting the two radiators holds the radiator in position. I don't even think about it anymore.
The second thing to brake was the kick lever, but as everyone on this site should already know, the 2002 kicker fixed this problem.
Rick
ShanMan:
Seems to me that the KX5 tranny is pretty good. my '87 still has all the original tranny stuff (minus seals, which have been replaced) and other than a notchy second gear seems to work fine. I think the most cronic issue with the older KX5's seems to be blowing out base gaskets. The newer bikes have the rubberized steel gaskets that apparently fixes this however.
Paul:
d**n Rick, the only radiator related problems that I've had is keeping the louvers on the bike :lol:
--- Quote from: Rick ---The first thing to go on ALL of my 500's (I buy a new one every year or two, so anything that happens is related to my riding) is the top radiator tab breaks at the 90 degree bend. On the first one in 1999, I had it fixed. However, after that first one, I just let it stay broken. To my surprise, because the radiator has 3 mounts, the other two mounts, plus the top hose connecting the two radiators holds the radiator in position. I don't even think about it anymore.
The second thing to brake was the kick lever, but as everyone on this site should already know, the 2002 kicker fixed this problem.
Rick
--- End quote ---
The bike has been around in its present shape for many years. One benefit is that the bugs are worked out and you have a very reliable machine on your hands. The downside... it looks like its been around for many years :wink:
Rick:
Paul,
Boy do I have a fix for you. If I had read your post before lunch, I would have taken a few pictures to post.
Like so many other KX500 riders, I, too, lost so many radiator louvers that kept a spare set in my van (oh yea, I posted a couple of pictures of the inside of the race van this morning). However, in the middle of the night, my brain found a solution (I hate when this happens, as I have to get up and draw pictures in order to remember. I designed an all steel tilt front end like this several years ago, all in one night. Ugh!)
I picked up two pieces of stainless sheet, maybe 1/16, about 1 inch wide, and long enough to extend from just past the top and bottom radiator shroud mounting bolts. I removed my shrouds from the bike, held the little plate on the edge of the radiator so both mounting bolts were covered, and marked the holes from the front side of the radiator. I drilled these holes just larger than the standard radiator shroud bolts so the bolts could pass through the holes into the little weird nuts on the radiator mounts.
Next, I drilled two holes evenly spaced in the middle of the bar, mounted the bar to the radiator without the shrouds, and drilled into the louvers. I installed two bolts to hold the louver to the bar, and then installed the shrouds which holds the bar in place on the radiator tabs. Viola! After a year of hard riding and racing, not one louver lost.
The only problem now is that my louvers last so long, they get looking a little drab. :lol:
Hopefully my explanation is good enough to follow. If not, maybe I can snap a few pictures.
In the past few days, I have also welded three nuts on my pipe to secure the pipe guard, and repainted with high temp paint. While I was at it, I sheared two pieces of 3/16 aluminum, and cut out two pieces of high impact plastic stuff to make a new, stronger chain guide. Mine was in pieces after hitting something (not sure what, as I did not even know it was broken until I washed my bike after returning home :roll: ), so instead of spending $30, I spent a couple hours in the garage with big green. Too much fun...
Rick
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