Maintenance & Technical > KX500 Original
Project KDX500 has begun !
drewh14:
How do you go about getting the KX street legal in terms of the DMV?
I'm not sure about NH, but here in MA its a P.I.T.A. The only two ways i've been able to figure out are make the bike street legal, ie lights horn blinkers etc, and then bring it to the state police for a "custom vehicle inspection". i believe that is the same sorta inspection a garage custom chopper with a self welded frame would go through. but I've heard its not easy to pass. And even harder for a OHV that was never meant for the road.
The alternative (that I know has worked for a buddy) is to find a street legal frame. I'm keeping and eye out for something like a 90's KLX300 or KLR250. Then "adjust" the frame number on the KX500s frame to match. Find an inspection station that'll look the other way, and presto!
Again, theres not much of an easy way to do it in MA
Polar-Bus:
This step was fairly straight foreward, and the fact I am using a '99 KDX200 wiring harness made this mod "almost plug-n-play. The only real modification was soldering a female bullit connector on to the lighting coil to plug into the KDX wiring harness :
The KDX voltage regulator has a convienent OEM connector:
The KDX headlight switch mounts nicely on the RH side of the bars, and plugs into the harness behind the headlight housing:
The headlight/ headlight switch sub harness' plugs into a red and black set of connectors under the fuel tank:
And lastly the rest of the CDI, frame grounds, and kill switch connections are all color matched, and you just plug them all together near the coil:
Polar-Bus:
A sweet OEM looking 2001 KDX500 A1 !!!
So that's it for now, this was a LOT of forethought, and i'm mentally spent. I still have to add a brake light banjo bolt switch to complete the swap, but i'm not worried about this now, as winter is almost here, and I will be only riding out on the ice.
Hope this thread detailed all the steps needed to do this swap well, and it will save you a ton of time !
Rich K.
drewh14:
That is absolutely gorgeous. I think you read my mind for what I planned on doing this winter, and beat me to it! Well now I have an excellent guide!
Thanks in advance!
barryadam:
If anybody wants to do this, I have a bunch of original KDX parts available.
No need to buy a whole bike for a few parts (unless you need a frame).
headlight sets, light switches, original rear fenders with lights, etc.
No wiring harness, no frame.
PM me.
Barry
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