Maintenance & Technical > KX500 Original
Project KDX500 has begun !
Johnniespeed:
When I installed the Moose lighting coil 2mm was not enough, I dont recall the exact measurement, but I think I ended up taking off between 3 and4 MM . I think I milled off about 1MM at a time, then trial fitted it until everything cleared properly. I also used the Moose voltage stabilizer. I used the Acerbis number plate/ light because I liked the look.The Acerbis uses the rubber strap type of mounting and have given no problems for five years. Your KDX plate/ light looks good too. That threaded hole on the center of the upper triple tree, is where I mounted the voltage stabilizer.
Polar-Bus:
Phase 3, the tail light. First tip for those of you who want something DOT compliant. The stock KDX tail light only has 2 wires which is a running light only. A neat swap trick I learned is that 2001 and up Yamaha WR250/450 uses basically the exact same light assembly, however the WR's use a 3 wire, running AND brake light. Heres a pic of both, The 3 wire WR light is on the left, and the KDX lamp is on the right: :
Both lights use a simple 3 stud mount :
So all's I did was drill the stock KX500 fender to accept the lamp. You want to make sure you place the lamp as far back on the fender as possible to prevent the tire from contacting the bolts on the underside of the fender upon a suspension bottom out:
And the semi-final install:
The only further mod I will need to do to the tail light is to seal the base of the lamp to the fender with some clear RTV silicone. The lamp base is flat, but the fender is curved so I don't want water and mud leaking past the lamp.
Polar-Bus:
The stock KDX200's mount the voltage regulator under the seat bolted to the top of the frame near the rear of the airbox. Here's a pic of the KDX200 mounting:
This location won't work on a KX500 as there is no room under the seat. So after severall options I found a secure, and convienent location under the LH numberplate. It also makes perfect use of the OEM connector to the KDX wiring harness:
The only issue I might have with this location is it's bolted to the plastic rear fender. Sometimes voltage regulators run hot, and might melt the plastic fender, so this is something I will have to pay close attention to.
SCKawi500:
Polar, thats a fine job you have done with the light kit, I have been wantng to do the same thing, just havent been intrested in buying that 450.00 kit. Thanks for the tips, are you going to install blinkers too? I wish I could so I could ride on the street ,that would be a lot of fun.
Polar-Bus:
--- Quote from: SCKawi500 on November 13, 2009, 01:37:22 PM ---Polar, thats a fine job you have done with the light kit, I have been wantng to do the same thing, just havent been intrested in buying that 450.00 kit. Thanks for the tips, are you going to install blinkers too? I wish I could so I could ride on the street ,that would be a lot of fun.
--- End quote ---
I am pondering over installing blinkers. Per NH DOT law, they are NOT required on a motorcycle. They would however be a nice convienent addition, but they add weight, and stick out (possible getting damaged off roading). I have heard that Kawasaki actually made a KDX200 "S" model in Europe that has FULL electrics, and even had oil injection, but info is slim on this model.
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