Maintenance & Technical > KX500 Original

SJJ's 1998 KX500 rebuild

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snoopjonnyjon:
The bike was bone stock when I bought it. Very minty for a 1998. There were a few little issues with it, but nothing serious.


I made a 500 look like a 80 sitting on it:cry:


I quickly discovered that the motocross sized tank was inadequate for the riding I do so I bought a Clarke Desert tank. At the same time I also bought an FMF Gnarly pipe and Powercore silencer. These add some low and mid to the bike, without a noticeable drop in top end. And I wanted the chrome. I also bought all new plastics and graphics to set the original plastics aside.



After a few tree induced knuckle injuries, I bought a set of hand guards.


Which takes me into this winter. I'm doing a full teardown and rebuild of everything.

snoopjonnyjon:










Kickstand set in place





UFO Ghibli headlight (KDX/KLX replica)

snoopjonnyjon:


Pulling main bearings off crank. Princess Auto to the rescue. Although the crank jig is genuine Kawasaki tool.




Pressing the crank into the RH case. This is where the crank jig comes in. it prevents the crank halves from pressing together.


Transmission all assembled and ready for install of the LH case.



Back together

snoopjonnyjon:
Next up was the Moose lighting coil. I later ran the wire through the factory loom (which took about an hour to finally make work! Also, the coil interfered with the flywheel, so I had to machine down the baseplate 2mm.



I neglected to snap pictures of clutch, kickstarter or water pump install. But, here is a bottom end just begging for a cylinder... which unfortunately has not yet come.


And then switched attention to the rear suspension.
Pulled off the swingarm and linkage. Cleaned everything with solvent, then water/greaser, and finally toothbrush. Then repacked all the bearings with white grease and started reinstalling.

Here is the lowpoint.


Swingarm and shock back on.





Rear brake back on.

snoopjonnyjon:
Cleaned up airbox and subframe, and put on the kickstand.





Here's my 3 graphics kits I got off ebay. All discontinued. 1997, 1998 and 1999.


And, the skidplate.

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