Maintenance & Technical > KX500 Original

Found a present after riding... broken exhaust mount tab

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bunk:

--- Quote from: Johnniespeed on August 09, 2008, 01:38:59 PM ---My new 04 KX500 did that when it was two weeks old.  I figured that welding it would cause a hard spot and it would break again next to the weld. I made a very simple bracket that slips under the radiator mounts and holds the pipe mount, four years later it still holds up great.
  John

--- End quote ---

do you have any pics of it?

Platypus:
I bought my 500 with the same mount broken.  Every 500 pipe mount breaks there at some point unless you fix it before you ever ride it.  I took mine to a muffler shop and the guy welded a piece of chromoly on with a nut welded to it also.  It's been fine since then.

Funny part is I asked about it on here before I rode it and people said fix it but ONE person said ride it.  Well that's the way I felt and I did and ened up snapping the lower mount off the pipe.  I just really wanted to ride it....it was worth it.

Mick:
A list of common breakage problems with my KX and others I ride with:
1.  Pipe mount bracket
2.  Silencer bracket
3.  Rear hub bearings (drive side)
4.  Kickstarter
5.  Frame
6.  Plating on carburetor slide
7.  Electrofusion plating on cylinder

These things would break so often I just built my own stainless peices in most cases.  There wasn't a lot I could do to prevent the plating issues.  All I could do was rebuild the motor and replate.  But despite all the breakage problems others and myself have had, I still don't know of anybody with this famous "2nd gear" transmission failure.  Makes me wonder where that came from?

WRXBRUMBY:
Hey Mick

I just did the full rebuild and I replaced 2nd gear, it wasn?t from failure but from excessive dog engagement wear. The nugget before me must have been hard shifting into 2nd under load. This could possibly cause this so called failure you speak of.

Hey bunk, I put one of those awesome tanks on order from Clarke. Bloody thing still isn?t in Aus yet. I have been getting mixed msg?s about what size they do. Yours is 3.9 gal yeah? Cause they are talking 4.0 gal, and also there is a 3.5 I think. Do you guys normally round up? If so this would explain the 3.9 being called a 4 gal.(just hope they bring the right one over cause the 3.5 one looks pretty sad)?? 

http://www.clarkemfg.com/cgi-bin/miva?Merchant2/merchant.mv+Screen=CTGY&Store_Code=CM&Category_Code=kawasaki

kaw rider:
depends on what welding you are doing,  discount your cdi box.

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