KX Riders

Maintenance & Technical => KX500 Original => Topic started by: supercub on July 13, 2012, 04:04:19 AM

Title: 89-04 engines
Post by: supercub on July 13, 2012, 04:04:19 AM

Sorry if this has been discussed before, I did a search but couldn't find a difinative answer. Are the 89-04 engines pretty much identical? If there is some differences what are they? Thanks for all insight.

Title: Re: 89-04 engines
Post by: dave916 on July 13, 2012, 09:43:48 AM

some 89 had smaller flwheel,
there are few slight differance in stator plates,flwheels , some stator plates have mounting holes for lighting coil
there pretty much identical ,may be a slight differance in head compression E1/E2 casting

Title: Re: 89-04 engines
Post by: sandblaster on July 13, 2012, 11:38:07 AM

Essentially the motors are the same.
Shift shaft changed in 94 to a larger diameter.
Shift lever changed in 94 to a larger diameter.
Stators were the same from 89-91, Changed in 92-96, changed again 97-04.
Fly wheels 86-89, changed 90-91, changed again 92-04.
I have head that the heads were different from the E-1 casting to the E-2 but I have not found any difference.
If someone has specs that say otherwise I'd like to see it so I can update my info:
http://www.oem-cycle.com/KAWASAKIKX500BIKEID.shtml (http://www.oem-cycle.com/KAWASAKIKX500BIKEID.shtml)

Title: Re: 89-04 engines
Post by: supercub on July 15, 2012, 01:29:22 AM

Thanks for the info so far. Does anyone have , or know where to find a "master list" of all the 500 engine parts with OEM part numbers for rebuilding?

Title: Re: 89-04 engines
Post by: allan1353 on July 16, 2012, 06:08:21 AM

Didn't they also change to a bigger kick starter  shaft in 94 ?

Title: Re: 89-04 engines
Post by: sandblaster on July 16, 2012, 11:40:52 AM

According to the book, the shaft is the same from 85-04. P/N - 13066-1056

Title: Re: 89-04 engines
Post by: allan1353 on July 16, 2012, 11:51:58 AM

My bad sorry.

Title: Re: 89-04 engines
Post by: Foxx4Beaver on July 16, 2012, 11:54:24 AM

Quote from: allan1353 on July 16, 2012, 06:08:21 AM

Didn't they also change to a bigger kick starter  shaft in 94 ?

When I broke my kicker on my 95,I borrowed my buddies 86 kicker,and it went right on with no problems.

Title: Re: 89-04 engines
Post by: sandblaster on July 16, 2012, 12:54:31 PM

Yeah they make a small design change and you get a different part number.
Since the shafts are the same just about all the years of kickers will fit on the shaft.
The only real potential problem is chassis design changes on the earlier models.

Title: Re: 89-04 engines
Post by: don46 on July 17, 2012, 03:46:13 AM

There was a change to the kickstarter, may not have changed part number but the design changed. the newer design is much beefier in the area where the AL and steel meet. I assumed that they were a different part number, but maybe not

Title: Re: 89-04 engines
Post by: sandblaster on July 17, 2012, 03:57:45 AM

Yep, I have not updated my interchange page online but here is the info on the kick lever:
FITS 98-04 KX500 - 13064-1201
FITS 92-97 KX500 - 13064-1165
FITS 88-91 KX500 - 13064-1134
FITS 87 KX500 - 13064-1130
FITS 85-86 KX500 ? 13064-1118
FITS 75 KX400, 79-82 KDX450, 80-81 KX250 KX420, 83-84 KX500

Title: Re: 89-04 engines
Post by: Foxx4Beaver on July 17, 2012, 04:39:31 AM

Quote from: don46 on July 17, 2012, 03:46:13 AM

There was a change to the kickstarter, may not have changed part number but the design changed. the newer design is much beefier in the area where the AL and steel meet. I assumed that they were a different part number, but maybe not

This would be the difference....quite substantial.


(http://i1179.photobucket.com/albums/x393/foxx4afoxx/mxz-x/HPIM0774.jpg)

Title: Re: 89-04 engines
Post by: sandblaster on July 17, 2012, 04:43:08 AM

What two years do you have pictured?

Title: Re: 89-04 engines
Post by: Foxx4Beaver on July 17, 2012, 04:50:34 AM

Quote from: sandblaster on July 17, 2012, 04:43:08 AM

What two years do you have pictured?

The new beefier one on the left,from what I was told...is for 88-04,it's on my 95....PN#13064-1201.

The old one is just a spare that supposedly came off a 97.