KX Riders
Maintenance & Technical => KX500 Original => Topic started by: motojason on April 29, 2014, 05:53:46 AM
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As picked up, January 2014:
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20140209_1750292411_zpsc2ca6fcb.jpg)
Initial tear down, February 2014: Shock reservoir bracket broken, forks seals blown, shock seal blown, engine TBD...
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20140223_1630071531_zpsa5f21a41.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20140223_1630246591_zpsdc401d33.jpg)
Frame cleaning pre-repairs and finishing:
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20140228_1924279291_zps26556948.jpg)
Engine: Bottom end needs crank rebuild + bearings/seals, idler gear, clutch plates, trans bearings, new washers and clips, and the left side case is cracked. Boo! Top end needs cylinder plating and piston...at least there are no power valve parts to deal with!
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20140329_1233444921_zpsab1d7cf2.jpg)
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some odds and ends here if you haven't already seen em...
http://www.ebay.com/sch/i.html?_sacat=0&_from=R40&_nkw=1985+nos+kx500&rt=nc
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Oooo, I love NOS!!!
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Parts arriving: Frame back from getting repaired, sand blasted, and powder coated. New Hi-Flite seat, rebuilt crank, NOS idle gear!!!... and lots of other goodies.
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20140512_1023480471_zpsbe33c1ab.jpg)
Still need to get rear shock done and the cases repaired. Making progress.
Won't be ready for the Unadilla Rewind this month, but hoping to have it done before September.
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Where did you pick that up from? Looks like the one I fixed up and sold 6 years ago. I think the guy I sold it to was either in Big Rapids or Battle Creek can't remember.
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(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20140512_1023480471_zpsbe33c1ab.jpg)
sweet seat!!
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Where did you pick that up from? Looks like the one I fixed up and sold 6 years ago. I think the guy I sold it to was either in Big Rapids or Battle Creek can't remember.
Got it in Somonauk, Ill. Purchased from second owner who got it from a friend that bought it new from Tuf Racing in Dekalb, Ill. This one had never been fixed up in its life. Think it still had the original front tire! Was completely stock except for a PSI pipe and in pretty poor shape mechanically, completely worn out.
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sweet seat!!
Thanks! I dig Hi-Flite. I was happy to discover they were still in business. Had one of their safety seats on my 83 125 back in the day and now have them on all of the bikes I have rebuilt in the last few years.
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sweet seat!!
I was happy to discover they were still in business.
good to know!...I haven't seen or heard of Hi-Flite in years.
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After a long break the project is back on track. Got some of the more difficult to source parts. Have a new kick start idler gear. Shock is at Race Tech. Cylinder plating done and found an original piston. Cases repaired and the motor is ready for assembly. Will post some progress photos soon!
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awesome!...I had forgotten about this project...looking forward to seeing the progress!
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Hey moto, that guy you bought the bike from, did he live at lake holiday? Farm land behind his house?
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Hey moto, that guy you bought the bike from, did he live at lake holiday? Farm land behind his house?
Yup, that is correct as I recall. It was an ebay purchase, but I picked it up myself. Why?
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awesome!...I had forgotten about this project...looking forward to seeing the progress!
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150122_1609326991_zpstqukvvba.jpg)
Just back from Race Tech!
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/85_KX5_Rad%20Shrouds_zpsre7ntopy.jpg)
OEM NOS!
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Those parts are lookin good.
What all did you have Race Tech do for you?
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Sandblaster, Race Tech refurbished shock body, shaft, and reservoir-I sent them about 2.5 shocks worth of parts in order to be able to build one good one. New gold valve / re-valve, rebound separator, and rebuild with new seals, head, oil, bushings, etc. New spring (5.4 kg/mm). They don't make a 275mm length spring in the correct ID anymore so they provide an aluminum spacer.
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The only problem I see is now you gotta get the forks done to match :-D
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Oh, I got the forks! Complete 89 KX5 front end. Total rebuild, new springs, custom valving and cartridges made by Michigan Engineering using modified KYB parts and some stuff they machine themselves.
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Nice.
Can't wait for the ride report.
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Nice.
Can't wait for the ride report.
nice project... the fork-swap is easy bolt on to the 85, because of the same bearing size till 2004 kx500 ...
cant wait to see more pics of the progress... 8-)
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Was just looking over the pictures and noticed that this thing a has a rear drum brake and no powervalve. Are you sure this isn't an 85. Looks like a really clean build though
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Are you sure this isn't an 85. Looks like a really clean build though
the B1 is an '85.
'86 was the 1st year for the rear disc, and also the last year for the vertical "uni-trak"
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Makes sense now........I thought they were getting major updates at the time so every year was getting a new letter acronym until 89
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(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/85_KX5_Rad%20Shrouds_zpsre7ntopy.jpg)
OEM NOS!
what'd you end up paying for the shrouds?...I had posted them in a different thread a few weeks back, and he was asking a pretty good price then.
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Thinking about a compression release. Has anybody done one on an 1985 head? It looks a little tricky with the fins and the locations of the plug and hose connection. I showed it to the guys at Racer's Toy Store (they did the cylinder prep and plating) and they were not too confident about how to place it without having a spare head to cut up and look at the water passage configuration. They suggested putting it in the top of the cylinder just below the head gasket, but I was not crazy about that idea.
Suggestions?
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I'd check with Larry. he'd be the guy to ask.
Plus his work is impeccable
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[quote\] what'd you end up paying for the shrouds?...I had posted them in a different thread a few weeks back, and he was asking a pretty good price then.
$125 ea. I have a set of shrouds from Nightmare Racing too that I will use when I go to the track. No one makes a replica that is exact to the originals. The Nightmare shrouds fit and are sold as 85-86 model, but they have a straight top, and look to my eye, more like the 87 shrouds or the earlier Kawasaki "works" bike shrouds. These NOS will go on the bike only to look at!
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you got an awesome deal!...he was asking $345 a few weeks ago.
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you got an awesome deal!...he was asking $345 a few weeks ago.
I was happy with it. Definitely money I did not need to spend, but so cool to have originals and they are extremely hard to come by. To be honest I was not expecting to get them when I made the offer. I was like Oh sh*** when he accepted and I had to send cash!
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I'd check with Larry. he'd be the guy to ask.
Plus his work is impeccable
I did contact him. He has not done an 85, but I think that he is probably my best option regardless.
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Was just looking over the pictures and noticed that this thing a has a rear drum brake and no powervalve. Are you sure this isn't an 85. Looks like a really clean build though
only for mike... here on this site you could see all changes over the years of all kx models... www.cmsnl.com
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I was happy with it. Definitely money I did not need to spend, but so cool to have originals and they are extremely hard to come by. To be honest I was not expecting to get them when I made the offer. I was like Oh sh*** when he accepted and I had to send cash!
here's another set for ya...
http://www.ebay.com/itm/Kawasaki-1985-86-KX250-Radiator-Shrouds-/281577977867?pt=Motorcycles_Parts_Accessories&hash=item418f5af80b&vxp=mtr
(http://i.ebayimg.com/00/s/MTIwMFgxNjAw/z/67oAAOSw-W5UxtIi/$_57.JPG)
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no "nicks or rub marks" on mine. :-D
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no "nicks or rub marks" on mine. :-D
you think differently than I do...I would buy those, and run THEM, because they ARE nicked already, but still look very good, and they are "correct"....
and I'd save the other ones you have for "show", or when/if you decide to sell the bike.
of course, these are just my thoughts...you do as you wish.
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I would agree with your thinking if I did not already have a set of new Nightmare Racing shrouds with new decals on them. I will have to 'settle' for using those on the bike when it is ridden. This project is already making my wallet light!
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This project is already making my wallet light!
haha, know that feeling!...and they say "crack" is addictive! :lol:
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haha, know that feeling!...and they say "crack" is addictive! :lol:
My GREEN habit is by the far the worst offender!
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My GREEN habit is by the far the worst offender!
yeah I know people that still smoke that stuff too :lol: :-P
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yeah I know people that still smoke that stuff too :lol: :-P
HA! I was talkin' KX green. Good one!
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HA! I was talkin' KX green. Good one!
:lol: I knew what you were talkin about....I was just being a wise a$$.
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Cleaned and prepped cases before lapping.
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150208_1243004051_zpsfdxyqbpg.jpg)
Lapping with Time Saver compound per Sandblaster's post on lapping technique.
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150208_131800439_HDR1_zpslfsrgrpk.jpg)
Replated cylinder lapping with head
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150208_140754073_HDR1_zpslucphbvy.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150208_140733237_HDR1_zpskgiqzdnd.jpg)
All new clips and washers for transmission
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150208_150656357_HDR1_zps37c8xswl.jpg)
Ready for overhaul. Need to do shift cam and shift link roller mod before assembly.
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150208_1507232901_zpsttqsdgva.jpg)
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Motorrad introduced me to Time Saver and replacing all the Cir Clips..
Both very good suggestions.
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Any pictures of the intake/exhaust port setup on your bike?. Curious to how they look compared to the newer power valved engines. Build looks awesome so far
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Any pictures of the intake/exhaust port setup on your bike?. Curious to how they look compared to the newer power valved engines. Build looks awesome so far
Here you go: Stock porting. New Nikasil plating, stock bore size.
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150302_123508288_HDR_zpsfmonthc4.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150302_123414924_zpswbiokhn3.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150302_123404996_HDR_zpsoyjibn2q.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150302_123339442_HDR_zpsdqpjobkt.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150306_105956849_HDR_zpsh2zwwwdq.jpg)
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Hey moto, that guy you bought the bike from, did he live at lake holiday? Farm land behind his house?
Yup, that is correct as I recall. It was an ebay purchase, but I picked it up myself. Why?
Bought my 93 k5 from the same guy in December. Had a freaking hovercraft in his driveway and tons more goodies in his garage.
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Jason, how about a BEFORE & AFTER photo?
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150208_140733237_HDR1_zpskgiqzdnd.jpg)
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Head back from getting a new compression release and thread insert. Great work by Larry Wiechman!
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150322_115119240_HDR_zpsvjpwj5x5.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150322_115049990_HDR_zpsakjlbscx.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150322_132644476_HDR_zpsrwlfmnrb.jpg)
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Hey moto, that guy you bought the bike from, did he live at lake holiday? Farm land behind his house?
Yup, that is correct as I recall. It was an ebay purchase, but I picked it up myself. Why?
Bought my 93 k5 from the same guy in December. Had a freaking hovercraft in his driveway and tons more goodies in his garage.
Too funny, guy was a character.
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Final engine assembly, May 2015:
New clutch plates:
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150507_161146702_HDR1_zpsqthliosi.jpg)
This Yam part fits perfect. Couldn't get the Kawi washer, PN listed as discontinued.
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150507_172445459_HDR1_zpsq81vdunm.jpg)
Piston mods:
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150507_191927806_HDR1_zpsiwb1g1dn.jpg)
Engine Complete:
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150509_090927375_HDR1_zpsostqnq2e.jpg)
Frame prepped for assembly:
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150509_173547066_HDR1_zpsqxzowzpc.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150523_151736718_HDR1_zpsdznubsvo.jpg)
PSI pipe, DG Muffler, 89 Forks and brake caliper, New B-Stone X30 tires:
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150525_173534202_HDR1_zpsnklqcojb.jpg)
Case saver made from some 1/8" aluminum flat stock with a hand drill and 4" grinder:
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150525_183232169_HDR1_zpss9g6tpml.jpg)
Nightmare Racing plastic, Hi-Flite seat, done!
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150606_112458560_HDR1_zpskpkbykio.jpg)
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150606_112445685_HDR1_zpsljfv1onr.jpg)
Unadilla MX Rewind 2015. Raced in the Heroes and Legends Team Cup Challenge with former Kawasaki factory MX riders Ron Lechien and John Dowd!
(http://i992.photobucket.com/albums/af44/Jason_Mark_Anthony_Colon/IMG_20150606_111706132_HDR1_zpsaijqi0nn.jpg)
Finally made it! Started this rebuild in hope of riding this bike at last year's Unadilla MX Rewind event. Took more work and had more set backs than I had anticipated, but it all worked out great in the end. Had an awesome time and have a really cool bike now!
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that's beautiful!
now I think a lot of us would like to see a video, so we can hear that baby runnin!!...nice job!
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that's beautiful!
now I think a lot of us would like to see a video, so we can hear that baby runnin!!...nice job!
Thanks! I have helmet cam footage from the Team Cup. I'll work on getting it up on YouTube.
This is the first and only 500 I have ridden and it is way different than my 125/250s! The compression release on the head sure helps getting it started, that kick start lever has a looooong stroke...
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Great job, the bike looks fantastic! How did you guys do at Unadilla?
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Thanks! I have helmet cam footage from the Team Cup. I'll work on getting it up on YouTube.
cool, let us know when it's up.
I got to ride with Dowd once, right on the tracks behind my house. He's good friends with Keith Johnson from Pembroke, MA...which is about 15mins away from me. Keith was a 9 time NESC Champion throughout the 90's who I regularly raced with.
One day in '98, there was a bunch of us practicing on the tracks that're about 400 yards behind my house in the powerlines...and all of sudden the two of them showed up, and just put everyone to shame. Dowd was on factory Yamamaha back then...and won Southwick that year too.
Keith and his cousin Dana Johnson are working vigorously with the new Southwick owners, to get it back on the Nationals schedule.
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That's awesome! Did you get to talk to him, or just ride with him? Either way that's a memory to cherish.
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oh yeah...we all talked to him and had some laughs for about an hour.
my 1st impression was how easy he was to talk to, always smiling, and you could see it in his face and personality, that he was a truly happy person.
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That's awesome! Did you get to talk to him, or just ride with him? Either way that's a memory to cherish.
Got to talk to John Dowd for awhile. Super nice guy, seemed a genuine enthusiast, and really down to earth. He actually came over to me to ask about my bike and talk about the 250 project he was working on. Out of all of the Legends in attendance I enjoyed talking to him the most. It was great all around, the Rewind is a must do event, and definitely attend the Thor dinner and bench racing session on Saturday night.