KX Riders
Maintenance & Technical => KX500 Original => Topic started by: snoopjonnyjon on March 02, 2010, 02:03:43 AM
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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.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/nisbet021.jpg)
I made a 500 look like a 80 sitting on it:cry:
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/mom018.jpg)
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.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/nisbet_3003.jpg)
After a few tree induced knuckle injuries, I bought a set of hand guards.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0163.jpg)
Which takes me into this winter. I'm doing a full teardown and rebuild of everything.
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(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0004.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0005.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0006.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0007.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0008.jpg)
Kickstand set in place
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0009.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0010.jpg)
UFO Ghibli headlight (KDX/KLX replica)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0011.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0012.jpg)
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(http://i106.photobucket.com/albums/m252/snoopjonnyjon/104_0016.jpg)
Pulling main bearings off crank. Princess Auto to the rescue. Although the crank jig is genuine Kawasaki tool.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0010.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0011.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0012.jpg)
Pressing the crank into the RH case. This is where the crank jig comes in. it prevents the crank halves from pressing together.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0014.jpg)
Transmission all assembled and ready for install of the LH case.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0015.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0016.jpg)
Back together
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0017.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0018.jpg)
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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.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0019.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0020.jpg)
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.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0022.jpg)
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.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0024-1.jpg)
Swingarm and shock back on.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0026.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0027.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0028.jpg)
Rear brake back on.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0029.jpg)
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Cleaned up airbox and subframe, and put on the kickstand.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0030.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0031.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0033.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0038.jpg)
Here's my 3 graphics kits I got off ebay. All discontinued. 1997, 1998 and 1999.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0035.jpg)
And, the skidplate.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0036.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0037-1.jpg)
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And my new piston, replated cylinder.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0039.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0040.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0041-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0042-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0045-1.jpg)
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Sand paddle mounted
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0059.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0060-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0061.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0062.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0064-2.jpg)
New front to match.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0072.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0073-1.jpg)
Repacking the silencer
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0070.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0071.jpg)
Forks off for rebuild. I did pull the triple trees and packed the bearings and reinstalled.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0074-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0075-1.jpg)
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I'll do the step by step stuff later on, as there were quite a few steps missed here. I have all the pictures, just not the time right now to tell the story. But here are a few complete teaser pics.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/102_0024-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/102_0023.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/102_0022.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/102_0021.jpg)
I still have a few things left to install, when parts arrive. Fork seals, fork guards, Devol aluminum rad guards, works connection frame guards, reed spacer, v force3 reeds, airbox mudflap, and the wiring for the headlight. It is running and riding again though.
http://www.youtube.com/v/4qMecD4xvhY
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awsome bike!!!! and where did you get that fx graphics kit??
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I got the graphics sets as old discontinued stock off ebay.
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Hey Snoop,
Looks like great work, I imagine the weather should be breaking soon. Cabin fever must be at about Defcon 4...
Let the Good Times Roll Big Guy!!! :-D
Tuck\o/
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No cabin fever for this guy. I ride in any weather! Here's an onboard video from riding my 1969 BSA Victor 441 (right foot shift, no signal lights, doing hand signals) around town last week. Riding antique street bikes in Saskatchewan, Canada in February :mrgreen:... I thought I was just doing it for bragging rights, but I actually had fun. I think I will go for a ride everyday I have a chance from here on.
http://www.youtube.com/v/MZHvdI2LmKQ&hl=en_US
If you check out some of my other videos on my youtube, you'll see a few snowmobiling videos as well.
And as you can see from the youtube video in the prior post, that sand paddle works pretty good on the KX in snow. The motor will be broken in by the time spring rolls around.
There's a lot of fun to be had in the winter time, especially since I built this workshop. The ability to build a big fire and start working on projects makes winter my favorite time of year.
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Snoop, that is a FANTASTIC looking bike. Great job!
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Great Job! Pics like this keep me motivated!
Fitz
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GOOD WORK FELLA, SHE LOOKS FINE.WHAT BRAND OF SKIDPLATE IS THAT AS IM TRYING TO FIND ONE THAT WILL FIT AN 86,AND THAT LOOKS LIKE IT MIGHT. :-D
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The skidplate is from Moose.
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Thank you for using photobucket for your pictures. That saves disk space for the site, in turn it helps keep the cost of the site down.
Pictures use up the most disk space on the site. Post all the photobucket pictures you want. If you lose or stop your photobucket account kxriders looses all the pictures.
When you have a picture that is special or unique post it with the kxriders attachment. That way it will not get lost.
Thanks for doing your part in keeping the site cost down. The bike looks great, now we want the action pictures. You know, the double back flip, 400 foot record jump, longest wheelie............you can do it.
http://www.youtube.com/watch?v=exiLWPUjqj0&NR=1
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I can post some action pictures from before the rebuild. All I've got are a few lame old farm boy stuff. Nothing impressive.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/PB110066.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2001.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_1928.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_1934.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/PB110108.jpg)
Here's one going wrong...
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/PB110105.jpg)
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Looks like my photobucket has exceeded bandwidth, so will be down for a month. Here's a youtube video of starting it up cold. Hadn't been started prior that day... first kick!
http://www.youtube.com/watch?v=Eh0RYuDuI88
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Looks like my photobucket has exceeded bandwidth, so will be down for a month. Here's a youtube video of starting it up cold. Hadn't been started prior that day... first kick!
http://www.youtube.com/watch?v=Eh0RYuDuI88
Pick 3 of your best pictures and post them through kxriders.
People are interested in your build.
Thanks,
Danger4u2 aka David J.
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Jon,
I would like to know what the heck do you grow on that Farm up there Eh?
Your bike'(s) are great, you obviously have been working with other equipment and all your stuff is either top shelf or waiting to be replaced by top shelf...
Don't tell me wheat :x, any wheat farmers I ever ran into wouldn't buy a new part to save their life...
Bailing wire and liquid steel is all they use for repairs..... :-o
Ok. well I have to confess, I am jealous of all you guys who do have the resources and ability to do such quality work. I couldn't list all the names of the members I admire as I would surely leave somone out.
Jon you just happen to have the most pics and vids and, please keep it up.
The only thing I find better than the bikes and shop et al. is that all the shots with people (that their face is visable)
Have grins from ear to ear or laughing... to me that's what it's all aboot. (canadian for about)
Alright now you heard my confession... They say the first step to recovery is admitting you have a problem...
I have a problem... My solution...
I shall give you a run for your money when I win the lottery, I already promised Kwackman & a few other guys
a nice gift when I get my first check. Then I'm gonna start to tour around looking for members to ride with, and do a good deed or two. :-D
Tuck\o/
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Tuck, you are gonna hate this, but we farm mostly durum wheat :-P, and yellow peas. Dad and I farm 2500 acres together a few miles north of Assiniboia, Saskatchewan. I make the 200 mile drive home most weekends. I also work as a design engineer on harvesting equipment for CaseIH / New Holland for most of the year here in Saskatoon. They've been very good for letting me take time off during seeding and harvest. Another side benefit is an excellent employee discount on equipment, that has actually had more of an impact to the bottom line than my salary. This fall we bought a new CaseIH 7088 combine that I had been on the design team of for 3 years. It was a very cool experience to buy a machine that I had a hand in designing. The frustrating part is going to come when breakdowns occur. I am sure we have all done this... you go to take something broken apart, and you find that you just can't quite take it apart the way you hoped to, and it ends up taking hours longer than hoped. At that stage you undoubtedly curse the stupid engineer that designed such a stupid contraption. I'm not going to be able to find a suitable scapegoat.
Most of the bikes I have gotten in the last 4 years, since I started working. Going through school, I rode junk. Still had a ton of fun though. 1986 Honda XL100 and a 1985 Honda ATC350X trike. When I started working, I just didn't know when to stop. I was allowed to work as much overtime as I wanted, and coming from farming and going to school, I was just in a habit working until the job was done. But with an office job, it is never done... there is always more. So I was putting in huge overtime, right around 500hrs per year. That's an extra three months of 40hr weeks that I fit into evenings and weekends. Plus, I was farming too. So, I had no outside life at all really. When I had free time, I would scour the classified and find any interesting bikes I could. Really, the chase of an interesting bike was my entertainment. I didn't actually get to ride much (I've put 1000kms on my Buell in 3 years, 200kms on my Triumph in 2), but I sure loved looking at them. Last February I was on a business trip in Iowa, watching the classifieds back home, and spotted the KX500 and KLX650R. I only had vintage dirtbikes, and the only modern stuff were my streetbikes, so I thought a dirtbike might be good to get back into physical shape. since university I had gotten into horrible shape. I weighed 270lbs, and looked about double my age. I needed something to motivate. I couldn't decide which to get, so ended up buying both the same day (different sellers). I had wanted a kx500 from the time I was subscribing to Dirt Rider in grade 7, so finding an old one with the same decal scheme as Jeff Emig just seemed too cool. The KLX650R (no relation to KLR) was an oddball I just wanted to try out. And it was a perfect bike to let my dad ride. It has proven to be a perfect bike with near-kx500 performance when givin it (very similar with a xr650r)... and is fine with lugging around with my dad riding it slow.
This year I spent a whole lot less time working overtime, and a lot more time out riding bikes. I made 13 trips to the forest, and burned through more VP fuel jugs than I can count. The only day-stopper was a broken kicker. The ground was just too loose to manage push starting. By the end of riding season (November) I was down to 245lbs, mostly just from riding. Since then I've really changed my diet as well, and have been working out pretty hard. I'm sitting at 224lbs now, which I figure 46lbs weight loss should be the best performance mod for a KX500 a guy can get. I'm not sure I can say it saved my life quite like the heroin addict, but it sure helped me start enjoying life more. I always stayed clean and lived on the straight and narrow, but I wasn't enjoying life much.
I suggest you don't get too jealous of my abilities, I can make some pretty dumbass moves. The bike is back running again, but I had a disaster when I first got it back together. It started up 1st kick after the rebuild, ran great. I rode it a lap around the yard, seemed ok. So I pulled into the shop since it was really cold out (February in Saskatchewan). A couple minutes later I pulled out again to go down the road to check all gears. First good, second, good... go to pull third and the shifter just flops and now had about 3 inches arch. I could have made a mistake anywhere between step 1 and step 300... but I made it on step 1. Engine back out, pull cylinder, split cases, and find the two shift forks in mixed up. That was a really depressing job, and made me question everything else I had done on it.
Anyways, there is my confessional. If you are ever up this way, there's a spare KLX650R you are welcome to ride. If you want to see some more of my bike pictures, I am on facebook. Jonathan Myers in Saskatoon, SK. Add me if you like. I will see if I can post photos from there on here. I think I might be able to since my profile is public. If they don't show, please let me know.
Here's a welcome sight to see on a Saturday morning...
(http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs241.snc1/8823_164151336083_524486083_4044783_2183154_n.jpg)
It rained 3 inches on us that day of riding.
(http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs261.snc1/8823_164151351083_524486083_4044786_8057420_n.jpg)
(http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs050.snc3/13767_185987621083_524486083_4240917_7808906_n.jpg)
Mid July, riding with my dad.
(http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs070.snc3/13767_185974361083_524486083_4240600_466256_n.jpg)
(http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs050.snc3/13767_185974391083_524486083_4240605_550711_n.jpg)
Catching a breather after about 2 hrs of riding.
(http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs050.snc3/13767_185981381083_524486083_4240729_3848064_n.jpg)
(http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs070.snc3/13767_185981386083_524486083_4240730_2486073_n.jpg)
A coworker of mine from england that I offered the KLX650R to for an evening. We went out after work. Long days this far north, it was about 8pm when this was taken.
(http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs050.snc3/13767_185981466083_524486083_4240743_6848897_n.jpg)
(http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs070.snc3/13767_185981476083_524486083_4240745_6918602_n.jpg)
Trying to extend the riding season.
(http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs050.snc3/13767_189648956083_524486083_4285823_3821004_n.jpg)
(http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs070.snc3/13767_189648971083_524486083_4285824_493559_n.jpg)
And the most recent, fresh rebuild shot.
(http://photos-g.ak.fbcdn.net/hphotos-ak-ash1/hs482.ash1/26413_359681251083_524486083_5187078_6865986_n.jpg)
And just a recent photo to show the difference the KX has made in my fitness since last summer. People say I look angry here... and you said there was always a grin in my photos :-D
(http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs238.snc3/22564_310743206083_524486083_5004163_559821_n.jpg)
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Jon,
Wow. Just wow.. .
Your Dad must be proud as a peacock.. I have known several small farmers when I was younger and as much as people poke fun at them it is a hard life. After High school I worked for a custom farmer and drove tractor for him for about two years. All in all those were great people to be associated with. I don't take that lifestyle lightly.
Honesty, Integrity, and work Ethic are not just words on a Hallmark Card.
Thanks for taking the time to write all that, I wish I had started taking more time to get to know people
Before I turned 40 somethin'.
Letters like that get people to thinkin' about where they're goin or what they've done. Reflective is the word I think... & Motivational.
People look forward to the photo's and vids. A picture is worth a thousand words they say.
And if the worst thing in your build was swapping shift forks your doin' O.K.
Dollars to doughnuts someone will be looking through your build and find that little bit about the tranny and double check themselves account they read/saw your posts. Thanks for the facebook info however i don't have a page, my wife and boys do, I'll se if I can check it out as an outsider..
Everyone has a story, I'll try not to let any get away without hearing.
Pax Christi,
Tuck\o/
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Just giving this thread a bump since the photobucket pics are up working again.
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That front headlight is great! Any pics of parts you need to install on the motor/stator....And where did you buy it.
:mrgreen:
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The headlight came from UFO, it is their "Ghibli" which is a KDX/KLX replica. The lighting stator is used came from Moose.
It required some grinding of the mounting tabs to clear the flywheel, and I needed to supply my own screws for it. I have ordered a Moose wiring harness, which is still on backorder. It is supposed to arrive this month. When it comes I will see if I actually have all the needed components of not. I am sure I will need some kind of a voltage regulator, and I don't know if that is in the harness or not. This is the only picture I have:
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A few from yesterday.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0018-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0015-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0016-1.jpg)
And a few action shots riding the KLX650R.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0014-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0011-1.jpg)
Pitching it into a donut here. From the roost you can see in the second pic, it worked out well, without resulting in a high side.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0009-1.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/100_0012-1.jpg)
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Here are a couple videos from saturday. Cant wait to ride it again.
http://s106.photobucket.com/albums/m252/snoopjonnyjon/?action=view¤t=MVI_3624.flv
http://s106.photobucket.com/albums/m252/snoopjonnyjon/?action=view¤t=MVI_3625.flv
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Hey S.J.J.,
Bike sounds great, Looks like great riding up in your neck of the woods.
Take Care,
Tuck\o/
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I've put about 10 gallons through it so I feel comfortable that it is broken in and I can beat on it again. The new motor rips, very happy with the performance. I am finally coming to grips with the new bars and suspension settings and feel better on the bike now than I did last year. It just took some getting used to.
Towards the end of the day, I practiced a few stoppies. I used to do these all the time on my Ninja, but this was my first attempt on a dirtbike on grass.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2083.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2084.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2085.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2086.jpg)
This looks hilarious because the rear is down from just landing from the stoppie.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2087.jpg)
My body position was pretty much out of control here.
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2088.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2090.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2091.jpg)
(http://i106.photobucket.com/albums/m252/snoopjonnyjon/IMG_2092.jpg)
I liked this one. Had the rear wheel about 20 inches up. And actually kept my feet on the pegs.
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Great lookin K5. Cant wait till I pick one up myself.
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Great work, sweet K5.