KX Riders
Maintenance & Technical => KX500 Original => Topic started by: jbehunin on September 06, 2010, 12:03:18 PM
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I found a pretty clean and unused 93 KX 500. After riding it one weekend, I knew right off the bat that it needed some TLC.
Well a few weeks have passed and now I am about 90% done. All I need now is some new plastic, seat cover, tires and graphiccs.
But I am kind of fond of the stock 93 look.
After tearing the bike apart, I found out that the top end had never been touched. The KIPS valve was ccompletely froze up from carbon build up. The bearings were in pretty good shape, and just needed to be repacked.
After cleaning and rebuilding the top end, new clutches, new valving front and rear with new springs on the suspension, this bike has come to life.
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that is a clean '93... good job
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Hey JB,
That bike is in great shape! I'll be looking forward to a ride report! :-D
Tuck\o/
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What a relief it must have been for the Kawasaki engineers to wake up from 1988-2004 knowing that most of the work was already done on the KX500 sitting there only needing a tweak.
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Nice 93 500 / time to get it dirty.
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very nice!!!! good job!!!!
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Nice! Got to love the kx500.
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After I got the bike together, I took it out for a ride. I was cautious at first, wanting the motor to break in properly.
Towards the end of our ride, I was a little disappointed in the bike. The bike ran great from the low end to mid, but fell flat on the top.
I asked around, and finally a buddy of mine, who happens to be a Kawi mechanic, told me to check to see if the valve is opening all the way.
Long story short, I tore the top end off of it.
The valves were installed close!!!
Well, my buddy did the KIPS mod that everyone raves about, and as I put it back together, I was giddy.
The bike fired right up, and it had a totally different sound to it. It sounded more crisp and throaty. A quick ride up and down the street put a perma grin on my face!
Well next weekend I will take it back out and try it again! :-D :-D :-D :-D
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Very nice ride man!!! Have fun on her!
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Out of curiosity, what is "the kips mod" hes refering to?
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I have no idea. Hes an old mechanic from way back when. He has been wrenching on Kawasaki's for a long time. I told him my problem, and what I wanted the bike to do. He said he modified the kips valve. as far as what he did, i don't know.
But the thing is crisp, and it will rip your arms out!!!!
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great job! If mine looks like yours at the end of rebuilt, I would be so happy!
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pipe looks like a gnarly desert.should go well at high rpm now your p/v works.looks real clean too.
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Out of curiosity, what is "the kips mod" hes refering to?
REad here.
http://www.kxriders.com/forums/index.php/topic,1367.105.html
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Where did you get that frame guard thing over the chain?
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Where did you get that frame guard thing over the chain?
which part?
the chain guide or the frame guard?
the frame guards I bought off ebay
http://cgi.ebay.com/ebaymotors/WORKS-CONNECTION-FRAME-GUARDS-KAWASAKI-KX-500-1988-04-/390246840159?pt=Motorcycles_Parts_Accessories&hash=item5adc86375f
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Ya! for That is it. But, I thought it was protecting the subframe from the chain.
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I wish! the chain likes to rub the subframe. I want to fabricate something that will help with that!
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I wish! the chain likes to rub the subframe. I want to fabricate something that will help with that!
I'm in the process of rebuilding that area on my subframe. I thought of hard facing it, but not sure if i want the chain to wear quicker than the sub frame....
i may just notch and TIG a new piece of alu in the wear spot, and deal with the wear again down the road...
I have been told the subfame is 6061 alu and 5356 rod is best to repair it with. Any thoughts?
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Here is a pretty simple mod that Team Green did when they were racing the KX500 in the desert. I have one of their bikes and it has several mods that addressed the very few KX500 weak spots. Just to name a few, Team Green fixed the exhaust mount attachment to the frame from cracking, they welded up the radiators (and used shims to grab more air) including welding the air bleed, reinforced the frame and welded a u-shaped piece onto the frame to protect the water pump, and riveted a piece of stainless steel to the subframe to eliminate the chain wearing through it. Do a search and you can see one of my posts on some of these mods, and I attached a photo of the mod that addresses the subframe wear.
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Thanks Tom!
Tuck\o/
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Thanks! I may have to do that!