KX Riders
Maintenance & Technical => KX500 Super Motard => Topic started by: Abbott on September 07, 2016, 01:37:30 PM
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I started this build in another section of the forum but I thought it would better fit from here on out. if you want to see previous work done to the motor, click the link below.
http://www.kxriders.com/forums/index.php/topic,16138.0.html
The plan for this KX is to mount...
748 triple trees
748 Showa gold nitride forks
748 brembo calipers and masters
748 stainless lines
ducati 5 spoke marchesini wheel
CBR300R rear wheel and brake assembly
05-06 ZX6R rear sets and rear master cylinder
Clip ons
bodywork will be either ZX6R or Ninja 650R from catalyst Composites
Ninja 650R tank
There will be plenty of machining and welding going on over this winter, that's for sure! But the end product is going to be all worth it.
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stock front end is off and old bearing races were removed. new bearings are on order and should be in soon. once they are in, I'll start measuring the spacers to adapt the triple trees.
(http://i98.photobucket.com/albums/l271/dakota318st/20160906_212551.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160906_212551.jpg.html)
Here are the showa Forks
(http://i98.photobucket.com/albums/l271/dakota318st/20160822_064444.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160822_064444.jpg.html)
front and rear wheels
(http://i98.photobucket.com/albums/l271/dakota318st/20160504_203023.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160504_203023.jpg.html)
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nice!...
this'll be one of those cool/fun projects to keep an eye on, as you progress with it.
keep them pics com'in!
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nice!...
this'll be one of those cool/fun projects to keep an eye on, as you progress with it.
keep them pics com'in!
X2
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Finally got around to making the triple tree adapter. pressed it with the bearing race into the head stock. the rest is all OEM Ducati that bolts right up together. minor details to finish up there. rear is next!!
(http://i98.photobucket.com/albums/l271/dakota318st/20160923_160657.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160923_160657.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20160923_160709.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160923_160709.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20160923_160727.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160923_160727.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20160923_165626.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160923_165626.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20160923_165658.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160923_165658.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20160923_165717.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160923_165717.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20160923_165805.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20160923_165805.jpg.html)
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Very nice work! You shouldn't ever run out of front brake with that setup. I can't wait to see how the bike progresses.
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hahah no kidding! it's practically 1-2 finger braking on my 748 and the KX will be almost half the weight. I can always remove a caliper and rotor if it's overkill
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made a little progress this weekend. bled the front brakes...nice and solid now. mounted up the left clip on, bar, kill switch and clutch pertch. pulled apart the rear suspension components to clean and re-grease. it sounded like a creaky bed before!
(http://i98.photobucket.com/albums/l271/dakota318st/20161008_163104.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161008_163104.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161008_163715.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161008_163715.jpg.html)
hoping to start making progress on the rear wheel this week or next. I'll have pictures soon of that work.
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just finished machining the rear wheel to fit the 20mm ID bearing. I'll be assembling the wheel this afternoon so more pics to come soon...
(http://i98.photobucket.com/albums/l271/dakota318st/20161015_075225.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161015_075225.jpg.html)
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well, my swingarm pivot bolt is shot. the shaft is absolutely butchered because a previous owner completely neglected to reinstall the bushing that rides in the bearing.
anyone know if a newer pivot bolt will work? the one I have has a 24.5cm shaft length (minus the bolt head) and is 15mm dia. at the shaft and has a 14mm thread at the end
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measured the wheel base on the KX tonight...came in at 1391mm with the axle closest in. my 748 is 1410mm...not bad considering the swing arm looked so long on this thing
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well it's been a little while since I've posted but I've accomplished a good bit of work since. the rear wheel, final drive and rear brake assembly are all mounted and centered! was so glad to get this part done. all that is really left to do is make some sort of alignment boss to keep the rear caliper mount from spinning around. shouldn't be hard to do though.
(http://i98.photobucket.com/albums/l271/dakota318st/20161108_184740.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161108_184740.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161108_184806.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161108_184806.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161108_185945.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161108_185945.jpg.html)
I also picked up a set of those Chinese radiators for the '88+ KX500's. I'll give them a shot and see how they do. I read mixed reviews about the alignment and broken welds but I won't be jumping this thing or going off road so I hope the welds do alright. already have the left radiator completely mounted. have to make one more small aluminum bracket tonight for the right side and they will be all set.
(http://i98.photobucket.com/albums/l271/dakota318st/20161113_133708.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161113_133708.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161113_150601.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161113_150601.jpg.html)
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here is a side shot with the tank propped up on the frame. I have it "mounted" by the front of the tank where it slides onto a couple rubber bumpers. I have to wait for my tail piece to come in so I can see how much I will need to lower the rear sub frame and get my seat height correct. then I can weld in some flat stock across the sub frame and make a mount for the rear of the tank.
(http://i98.photobucket.com/albums/l271/dakota318st/20161112_150632.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161112_150632.jpg.html)
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That is coming along nicely.. Great job..
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that's lookin sick!!
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trying to research some tachometer options. I really want to put an analog tach on this thing. never cared much for the digital screens really. I keep reading posts about a 4 stroke tach only reading half of the RPM's because of the wasted spark that the tach is set up for.
anyone know a way around this?
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hey guys. looking for some knowledge on this...my reeds have this piece installed that blocks part of the flow area. I checked a parts fiche and this piece isn't shown separately. just wondering if it's aftermarket or OEM and if it needs to be there or is used on the newer generation 500s as well. I plan on using this bike on an asphalt track at high speeds so to me it would make sense to have the highest flow as possible
(http://i98.photobucket.com/albums/l271/dakota318st/20161125_154424.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161125_154424.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161125_154435.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161125_154435.jpg.html)
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anyone have any ideas about the insert that goes into the reed cage?
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Has the carb boot been modified as well?
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no, it is stock. straight thru.
do the newer Gen kx500's have anything like that?
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never mind. you guys are right! I was going off memory (which isn't much!) when I thought the carb boot was straight thru. it is offset so it makes sense to have that insert. Makes me feel better it isn't just some random thing thrown in there.
got the new boyesen reeds installed last night. tore down the carb and sonic cleaned the entire thing.
new reeds on the left, old ones on the right...
(http://i98.photobucket.com/albums/l271/dakota318st/20161130_185710_001.jpg) (http://s98.photobucket.com/user/dakota318st/media/20161130_185710_001.jpg.html)
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got the tail section in from Catalyst Composites. love the shape of this thing but it's too wide. had to thin it up. cut out the section of the painters tape. I'll eventually reinforce the underside and bonds the top. I'll also have to shape the front of it to match the tank....when it's 1 pc. again hahah
(http://i98.photobucket.com/albums/l271/dakota318st/20161216_195819.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161216_195819.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161216_203116.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161216_203116.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161216_203032.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161216_203032.jpg.html)
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prepped and reinforced the tail section tonight. should start fitting this weekend
(http://i98.photobucket.com/albums/l271/dakota318st/20161221_193509.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161221_193509.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161221_203222.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161221_203222.jpg.html)
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have the tail shaped how I want it now and bondo'd. Ready for primer and paint once I drill the mounting holes. Looks funky with out tires and having the suspension completely decrompressed. can't wait to get some on there.
(http://i98.photobucket.com/albums/l271/dakota318st/20161226_125545.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161226_125545.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20161226_125443.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20161226_125443.jpg.html)
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I like the back rest hump to hold down the front. Can't wait to see it's results :evil:
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Your doing a great job.
I've been so busy that I lost track of your project.
On your reeds, the Rads are good for lower to mid range but if you want the most out of your engine on top you really need a V Force 2.
You will also need to mod a few things as well..
You might want to take a gander at this post.
http://www.oem-cycle.com/forum/viewtopic.php?f=5&t=484 (http://www.oem-cycle.com/forum/viewtopic.php?f=5&t=484)
This was all Motorrad's fault 8-)
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Your doing a great job.
I've been so busy that I lost track of your project.
On your reeds, the Rads are good for lower to mid range but if you want the most out of your engine on top you really need a V Force 2.
You will also need to mod a few things as well..
You might want to take a gander at this post.
http://www.oem-cycle.com/forum/viewtopic.php?f=5&t=484 (http://www.oem-cycle.com/forum/viewtopic.php?f=5&t=484)
This was all Motorrad's fault 8-)
Thanks Sandblaster! Only issue with the VF2 reeds is that the mouth of the '85 intake only have a 4 hole bolt pattern (1 at each corner) where the newer gen K5's have a 6 bolt pattern...not sure how I would get around that.
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Ah... Forgot your running a 85 engine.
I'd make an adapter plate out of 10mm thick aluminum.
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great to see something crazy like this! can't wait to see it running.
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https://youtu.be/huDA4Veu0FQ
here is a video of my '85 K5 head on the mill yesterday. took .020" off of it. had way too much room in there for the squish band. Even now after the machining, I reassembled the head and measured 1.8mm. There is so much room because I am running the newer style 2 ring piston which has a flatter piston dome. I may eventually need to get a custom head gasket made to get it lower but I'll see how it runs first.
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Threw some temporary tires on the bike to make it a roller! finally!! I can actually move this thing around now.
installed the petcock last night. but of course, I had no gas in the garage so I couldn't test to see if it leaks yet.
got my Motoholders front fairing stay. hopefully weld up the mounts for that and the rear tail section tomorrow so make them permanent.
(http://i98.photobucket.com/albums/l271/dakota318st/20170118_202815.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170118_202815.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170118_200142.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170118_200142.jpg.html)
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Starting to take shape nicely!!! Looks pretty d**n bitchin
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made lots of progress tonight. quite a bit of welding done. fairing stay mounts, fuel tank front mount, tail section mount.
coming together! photo compliments of my friend who let me borrow the welder.
(http://i98.photobucket.com/albums/l271/dakota318st/21749.jpeg~original) (http://s98.photobucket.com/user/dakota318st/media/21749.jpeg.html)
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I can't wait to see your progress. You're doing some really nice work!
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Fun build. Nice looking bike!
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fit a 748 rear shock on the KX. milled up some .250" brackets to adapt it. turned out nice. should work better than the original 85 shock. I turned some spacers to fit in between the lower shock brackets so I don't have individual bolts like ya see here. need to order some longer bolts.
(http://i98.photobucket.com/albums/l271/dakota318st/20170217_172713.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170217_172713.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170217_172657.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170217_172657.jpg.html)
sneak peak of the bodywork on. since, I've had the top fairing fastened to the sub frame. sits farther back now. Looks too far forward in the picture but ya get the jist.
(http://i98.photobucket.com/albums/l271/dakota318st/20170217_174815.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170217_174815.jpg.html)
also have the rear set brackets done. they are getting a clear anodize put on them. I'll have rear brakes when I get them back!
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That dude is going to look bad ass when you get done. What colors are you going with?
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thanks Umberto! excited to get it done.
Kawi Green of course!! is there another option?! hahah. it'll have a scheme pretty much like the upper and lower fairing you see in the picture. have to cut up the fairings a little so I'll be putting new paint on them
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installed the trail tech gauge last night. Mostly using it for the tach and water temp sensor. maybe i'll add the speedometer sensor down the road. also finally have the rear sets on. next is fabricating the shift linkage...this one is going to be a bit tricky...
(http://i98.photobucket.com/albums/l271/dakota318st/20170307_205452.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170307_205452.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170307_202231.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170307_202231.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170302_185949.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170302_185949.jpg.html)
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Very nice work!
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Hey guys. Been a while since I've posted but there has been a decent amount of progress on the KX. Spring time gets real busy for me. I have my full time job and wrench on Ducati's as a side gig (this is my fun money, hence the KX LOL).
Just got my rear wheel back from powder coat and put the new tire on. also had them powder coat the chain adjuster blocks, chain alignment pieces and upper motor mounts (a lot more stuff still to be done yet!) put on a superlite sprocket and DID chain. Also have the TOPAR sprocket cover recommended by some of you folks. Took an ohlins steering damper from a GSXR 750 and mounted it to the frame and a ProTek fork mount. should perform very well. have to send the damper out for a rebuild however.
Next is the bodywork!!! wooooo!
(http://i98.photobucket.com/albums/l271/dakota318st/20170426_203536.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170426_203536.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170426_203600.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170426_203600.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170319_155918.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170319_155918.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170319_155953.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170319_155953.jpg.html)
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Hey guys. Been a while since I've posted. All the mechanical fabrication is complete so it's been mostly a lot of finishing work. Getting pieces powder coated and painted. sanding the tank and tail down tonight to get it ready for primer and hopefully paint this weekend so long as the weather allows. Taking it to mid ohio in 2 weeks so it has to be ready by then! LOL wish me luck!
(http://i98.photobucket.com/albums/l271/dakota318st/20170621_212124.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170621_212124.jpg.html)
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finally got to ride it down my street for the first time! still trying to get the carb set up just right. I've adjusted the float bowls, needle position, pilot and main jet and it is getting closer. still doesn't have nearly the throttle response I'd like at 1/8th turn to 1/2 but once this bike opens up on the pipe, wow does it move!
(http://i98.photobucket.com/albums/l271/dakota318st/Mobile%20Uploads/20170701_093603.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/Mobile%20Uploads/20170701_093603.jpg.html)
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I can't see or find what carb your using..
If it's a stock carb I would swap it out for a 38mm Keihin quad vent air striker.
You will gain HP through the entire RPM range and quicker throttle response.
Dyno proven.
If you want a used one, 96-97 KX250, 2000 Cr250.
You will need the throttle and cable from whatever you choose.
Or, you can buy a new one from Sudco for around $200.
Then again, getting your jetting dialed in will have a huge effect on throttle response.
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awesome sandblaster! thanks for the heads up. I am heading to mid ohio this weekend with the KX so it won't happen right away but that will certainly be something to upgrade then...
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Man, that thing turned out nice! I'll bet it looks wicked with all the fairings on it. We need some video of it in action.
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here you go Umberto! (video will be after the weekend)
(http://i98.photobucket.com/albums/l271/dakota318st/20170705_232235.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170705_232235.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170705_232150.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170705_232150.jpg.html)
(http://i98.photobucket.com/albums/l271/dakota318st/20170705_232205.jpg~original) (http://s98.photobucket.com/user/dakota318st/media/20170705_232205.jpg.html)
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Incredible build, well done!
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That thing looks wicked, great job!
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What did you end up doing for a starter?
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thanks guys! I began making a roll starter for it. have all the parts and pieces for it but did not have time to finish fabricating it. for now, I will have to unbolt the right rear set (2 bolts) and the brake reservoir bracket (1 bolt) so I can just kick it. or have my buddy push start me for a couple sessions LOL
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The "buddy starter", I like it. :-D
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do we know what it weighs?
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I'm not sure yet Foxx but I am eager to find out! my buddy has some car scales he is going to bring over sometime...probably could get away with a couple bathroom scales with this one though hahah. i'll post up the results when I find out. will be a little while
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I'm not sure yet Foxx but I am eager to find out! my buddy has some car scales he is going to bring over sometime...probably could get away with a couple bathroom scales with this one though hahah. i'll post up the results when I find out. will be a little while
yeah I'm quite curious too.
absolute phenomenal job!
you should e-mail Kawie those pics if haven't already, just to see what their response is.
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If Kawi ever decided to build a street legal 500cc 2T twin for the street, I'd buy it... Take it apart... Modify it... And then scare myself to death on it :-)
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If Kawi ever decided to build a street legal 500cc 2T twin for the street, I'd buy it... Take it apart... Modify it... Pay my life insurance policy... And then scare myself to death on it :-)
Fixed it for you. :-D
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:-D :-o :lol: :-P
But true...
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finally picked up an Imgur account. fit my ohlins rear shock on tonight along witb some woodcraft clip ons. also have a ducati 749 top triple to mount but i have to take that into work a trim it down a little. will post more pictures soon
(http://i.imgur.com/0bB01JA.jpg)
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Looks Great! :-o
What swing arm did you use?
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Looks Great! :-o
What swing arm did you use?
it's the stock '85 KX500
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Ok, that's what I thought.
Have you given any thought to stiffening it?
I noticed with my Supermoto setup that the swing arm really flexes a lot.
I wondered if it would perform better being stiffer..
To test, put the bike leaning against a wall, then push the top of the rear wheel towards the wall...
Mine really moves.
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no i havent. certainly would perform better if it was braced. ill have to check mine when it comes off the lift.
last night i updated the top triple tree to a ducati 749 set up with 53mm woodcraft clip ons.
(http://i.imgur.com/wyuZXX1.jpg)
(http://i.imgur.com/7YQXoW8.jpg)
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hey guys. havent posted in a while. fitted the KX with an ohlins rear shock and had Larry decomp the head. fires right up with the roll starter now. need to respring, revalve the shock next
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Weird. I could see the pics last night, now some of them I can not. It is coming along! Looks great!
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Weird. I could see the pics last night, now some of them I can not. It is coming along! Looks great!
I got one to work, but not both. Abbott, you can now post pictures directly to the site instead of using Imgur or Photosuckit. Here's a handy guide:
http://www.kxriders.com/forums/index.php/topic,17107.0.html (http://www.kxriders.com/forums/index.php/topic,17107.0.html)
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Weird. I could see the pics last night, now some of them I can not. It is coming along! Looks great!
I got one to work, but not both. Abbott, you can now post pictures directly to the site instead of using Imgur or Photosuckit. Here's a handy guide:
http://www.kxriders.com/forums/index.php/topic,17107.0.html (http://www.kxriders.com/forums/index.php/topic,17107.0.html)
got it! thanks umberto. much nicer doing it that way
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You're welcome. Did you ever get some video of the beast in action?
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unfortunately, no. My gopro is an original hero model and I think its well past its prime. sound is shot on it and the battery dies after a minute or two. video quality has gone down hill as well. eventually I'll borrow a buddies and throw it on youtube
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Finally got a weight on this beast.
Semi wet weight (~1/4 tank of fuel) - 256lbs!! :evil:
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We really need some video of this beast. Even a simple phone video of it roaring by. Withholding video is cruel and unusual punishment as defined by the Geneva Convention or some other treaty I'm sure. :-D
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We really need some video of this beast. Even a simple phone video of it roaring by. Withholding video is cruel and unusual punishment as defined by the Geneva Convention or some other treaty I'm sure. :-D
hahah! I will work on it. the bike is going with me to Mid Ohio for the vintage days weekend (July 7th & 8th) and then doing a track day on the 9th. should have some video for ya then! more than likely will sneak it down a farm road before that though :evil:
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https://youtu.be/DcvHh1vHZ_k
There is a teaser to get ya by LOL next time it will be riding video
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https://youtu.be/DcvHh1vHZ_k
There is a teaser to get ya by LOL next time it will be riding video
That dude sounds like it means business. I can't wait for the track video.
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That is very nice! Can't wait to see vids of it in action!
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https://youtu.be/fCopS2fn1bE
Have some video from mid Ohio. Good test day all around. Bike made it out for all 7 sessions. Still a few thing to sort out but it's getting there! Sorry that the camera tipped a little. Next upload won't have that.
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Very nice... 8-)
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Awesome! Are you going to film some race footage?
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That's awesome. There's so many threads that never end in a functional bike. Really cool to see this out there ripping.
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Awesome! Are you going to film some race footage?
eventually I will get some. not entered in any racing yet. I am not even sure what class I could register this thing in really LOL
plus I don't have the coin to go racing yet. trying to build a house this year. once that is out of the way, game on!! still a lot of testing/tuning to do before I get to that level also
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Also, my buddy followed me down the back straight on his 749 and said I was right around 115mph!! not bad for a dirt bike!
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Video of an afternoon session. Better camera shot
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Hey guys. quick question...can a newer power valve style KX500 motor fit into my '85 frame?
My motor is fine and running good. but when the time comes that it doesn't or if something ever went drastically wrong, I am thinking an upgrade to a newer style motor is in order. parts are more readily available and just feel it would be a nice upgrade to the non-powervalve '85 motor.