Maintenance & Technical > KX500 Original
Chronic problems?
Rick:
dang, forgot to talk about the radiators....
I took a look at Brian's radiator mods a couple of years ago, and have never understood why Kawasaki replaces the plastic plug with a weld, as I don't think this thing has a chance of leaking. I also checked out the other mods, and elected not to mess with the radiator tank crimp either, as I have never seen just a tank leaking after a crash. Almost every ride/race ending radiator failure I have seen involved damage to the down tubes.
With that said, the one area I would consider reinforcing with a weld is the bottom radiator hose bib, as this is just a press fit. A pretty good rap on the radiator in a crash can cause a little leak here. I hit a tree dead center on the shifter side radiator several years ago in the woods, and the radiator started leaking fluid there. (suprisingly enough there was no other damage to the radiator) The simple fix to finish the ride was to just loosen the radiator cap (usually not a good idea, but better than pushing the bike back to the truck.) Once back at the truck, I layed the bike on it's side, pulled the damaged radiator, and wrapped a little Locktite epoxy around the neck. Sold the bike a year later with this fix still installed, and it's still running strong.
Another crash involved hiting a stump on the bottom of the shifter side radiator sooooo hard that is twisted the bottom of the radiator about 30 degrees. The radiator held strong, but (unbeknownst at the time), the fuel line was pulled off, resulting in the bike draining all this precious fluid onto the ground. Mylers twisted the radiator back in shape for only $75.
I guess the point here is that if I were factory KX, I would eliminate ALL variables, and weld the radiator solid. But for the privateer racer/trail rider, the money is probably not worth spending.
Keep up the postings, your info is great food for thought...
Rick
teamgreen500:
Rick & Co.,
Good point on the bibs, they're welded also. I had a radiator leak at the "folded" seam once while ridin' a '90 500 Realllllllly hard at Pismo. It only did it just a little and it was replaced soon after; however, during a Hollister Hare-scramble and a Clear Creek enduro (the radiators were used by a friend) there were no leaks later!(go figure).
I know that welding the radiators is pre-DH and I remember LR having welded radiators on a '89(?) "White" KDX200 during a Baja pre-run. Also, on his "Over-Lit" 500 race bike that year...if you know what I mean.
About KX5 tranny problems: While I went down to So Cal this weekend (I live in Redding...600 miles to the North...trully Northern California...) I dropped the motor off at Team Green (And got an eye and earfull of Chicken's K5 Super-mo AND his/Kawi's K250F Super-mo...Hotter than Pam Anderson at "The River.....") and then went over to Chapparal to pick up a new WR450 for a friend....$6300 out the door, thank you Sean Hummel...and Sean was telling me this story about his '87 K5 back in the day............(Wayne's World video fade effect starting NOW................):
Sean starts telling the story as his eyes look off into the past and you could see him going back in time in his mind...
"So, I'm on the starting line @ Sand Hill and I'm putting my goggles on while my dad is warming up the motor...when all of a sudden the bike takes off over the starting gate without me! It just took off OVER THE STARTING GATE and I was left on my butt where my bike WAS!
It turns out that a spring in the tranny or the clutch, some-where in their just failed..so your little mishap isn't that unusual..."
So, I guess our friend from the U.K. may have diagnosed this one or, at least, I hope it's straight forward.
Here's another thing: On Thanksgiving day I was THROWN to the ground by a locked up/locking up rear wheel that was not explainable. I am totally capable of accepting "Pilot Error"; however, when you are landing straight as an arrow on a "Double Downhill" jump for the 20th time and you feel the back end "drag" and hi-side you into the X-ray room...well, we thought it was the rear brakes (I was using a set of wheels with desert/heavier/thicker discs...that had never been a problem before or since!)
So now that I've gone thru this (Remember, when I restarted the bike after the "Mystery shift" it would "drag" itself to a stall as I released the clutch) I'm wondering if it's related to my Down-Hill-SLAM!
Oh, and another thing I learned while I was down there: A friend of mine bought LR's '98-'99 MacPherrson Racing class 7U S-10...you know, the truck that he SPANKED everyone with in Baja...it's a small world. I love having another reason to Pre-run the 1K! Come on November!
Hmmmmm....now where do I get a Desert Tank for a KX250F? I mean, I gotta keep it fair for all those guys pre-runnin' on 4-strks...don't I?
Well, I'll get some Digi-pics when I go back (K5 and KXF Supers) to get my motor and I'll post'em here....or if anyones going to the "Dealer Show"...they'll be there.
Now, does anyone know anything about a really trick KXF with "Chevy" graphics and "259" on the # plate...Hmmmmmmmm?
And another thing...Kawasaki couldn't be building there own KX450F and tellin' Suzuki,"No thanks" to there 450...could they? Would it look just like the 250F with very slight frame changes and a motor that's "Just a little" bigger looking? Could it be a 4-speed? Will they make "KD" versions? Are they making they're own after-market goodies ala "GYT"?
Na...it must just be RUMORS!
Gawd, I love a good "Forum"...you hear the darnedest things....
Manny
teamgreen500:
YES! I'm so HAPPY!
Just got off the phone with Johnny Braasch at Kawi!
"I know what's wrong without even opening it up...sometimes...actually, I've only seen it about 6 or 7 times, a gear will 'weld' itself to the shaft. I think it's second gear on the output side. I'll have it done in about a week!"
You see, this is a big deal to me because of ALL the K5s I've had, this is my Eleanor! This bike has been thru a Head-on, Crazy Trails from Hell rides, Track-time that would raise the hair on your neck and even some pre-running that was FASTER then the race itself.
So, now I'm going to get it all prep'd for racing AND pick me up a KLX 400 or build a new KDX500SR for pre-running.
Now, where can I find 2 level headed Expert off-road riders that're OVER 40 and want to see all the young kids cry when we whhoooooop their A$$E$ at the BITDs next year?
Anyone, Bueller, anyone...?
BTW, I AM NOT KIDDING! OOOOHHHH RAHHHHHH!
Manny
Paul:
Rick, he's got your number as I'm not old enough :lol:
teamgreen500:
Anyone, Bueller, Anyone?
Manny
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