KX Riders
Maintenance & Technical => KX500 Original => Topic started by: byron909 on January 30, 2011, 03:42:53 PM
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about 3 years ago i aquired an 86 kx500. it was hammered in every way you could imagine. the motor was out of bike, had a busted up case, broken clutch cover, cracked/ broken clutch actuator/ chain guard, lots of little things. you name it, it wqas probably shot/ broken on the chassis. fork seals, shock seal/ bumper missing, shock preload ring stripped on body, frame cracked in about 4 places. there were no lower engine mounts, the swingarm pivot was loose, the upper mounts loose, front mounts broken. radiators tweaked/ smashed, etc etc. nothing on the rear wheel was usable. the swingarm looked like the chain came off a hundred times.
pic of bike. doesn't do justice to how wrecked it was
(http://inlinethumb32.webshots.com/47775/2768827880035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2768827880035658722xhzmBu)
(http://inlinethumb14.webshots.com/32333/2729579900035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2729579900035658722vjjnqp)
my plans originally were to use the motor for an 08 kx450f i had, but i grew up riding 80's kawasakis and couldn't scrap this thing.
so it sat untill last year sometime when i decided to overhaul it.
i started with things i knew i needed to do. never liked the mini footpegs, so i made some 02 up cr/f foot pegs work
(http://inlinethumb01.webshots.com/23936/2549914660035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2549914660035658722koWjmh)
then was the pipe. every old kawaskai i have ever owned had a pipe that rattled. this bike has one small mount under tank. so i started to weld more tabs here and there, but also beeefed up the one that was already there. used mainly honda mounts everywhere. my pipe had been repaired liek a zillion times, so i had to fix as well
(http://inlinethumb44.webshots.com/4459/2284085370035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2284085370035658722UjjECq)
(http://inlinethumb50.webshots.com/26161/2391906930035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2391906930035658722vDswBC)
new lower mount
(http://inlinethumb21.webshots.com/44756/2127046760035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2127046760035658722hBJWrw)
started with hacking off the rigged stuff
(http://inlinethumb14.webshots.com/19981/2433149990035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2433149990035658722smOHYO)
new upper mount, made from 5/16
(http://inlinethumb60.webshots.com/9531/2331705300035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2331705300035658722jATjCT)
new rear mount
(http://inlinethumb40.webshots.com/22055/2122660920035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2122660920035658722rnhJux)
blasted, de carboned and ready for ceramic
(http://inlinethumb15.webshots.com/47310/2095882910035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2095882910035658722QSqjzo)
ready to mount
(http://inlinethumb15.webshots.com/6734/2754148510035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2754148510035658722AGbbil)
i had a 88 up silencer already, it bolted right up to the 86 mounts
(http://inlinethumb23.webshots.com/47190/2740000500035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2740000500035658722AYcnRq)
silencer de carboned, 2.5" trimmed off, packed and ready for use
(http://inlinethumb27.webshots.com/47194/2238725550035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2238725550035658722ygpxGX)
oem fuel tank, looked typical for old kx
(http://inlinethumb54.webshots.com/41717/2457173070035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2457173070035658722tJoHdP)
found a smaller 86 kx250 tank, it was pretty bad looks wise as well, cleaned up and ready to mount
(http://inlinethumb14.webshots.com/24781/2160722120035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2160722120035658722ppdqVx)
wanted a skidplate, had some 450 thing, hacked up to make fit.
(http://inlinethumb26.webshots.com/20761/2700428050035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2700428050035658722LjhoNo)
made a new front hold down, notched hole for drain plug, fits the kx frame perfect now
(http://inlinethumb26.webshots.com/25/2729664580035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2729664580035658722ZrxGwR)
(http://inlinethumb49.webshots.com/40496/2348713990035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2348713990035658722LrvJTa)
cases coated with heat dispersant, ready to go together
(http://inlinethumb50.webshots.com/33073/2818667870035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2818667870035658722ZOQPCG)
shift parts moly coated
(http://inlinethumb30.webshots.com/1501/2402561260035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2402561260035658722QMtYqE)
getting motor together, surf and turf racing balanced/ rebuilt the crankshaft
(http://inlinethumb57.webshots.com/41208/2730995800035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2730995800035658722AfLado)
slotted clutch basket, drilled hub
(http://inlinethumb33.webshots.com/44896/2976243460035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2976243460035658722qYSqyg)
hammered radiators
(http://inlinethumb57.webshots.com/47544/2974164450035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2974164450035658722Guvndy)
planned on using 88 up radiators, just a few things different than 86 model
the right side on 88 up is hair shorter, so lower mount tab needed to be lengthened, and middle mount on 88 up is on rear, 86 needed it in front. 88 up also has two shroud mounts, the 86 has one in center
(http://inlinethumb43.webshots.com/46826/2511126620035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2511126620035658722lgyaxW)
the left side is exactly the same minus the midle mount and the shroud mount
(http://inlinethumb04.webshots.com/45891/2138121290035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2138121290035658722WTfrss)
radiators all welded up, coated with heat dispersant. need to drill the hole for shroud mount. these are some oversize jobs
(http://inlinethumb57.webshots.com/47160/2563333680035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2563333680035658722IhsMCi)
for the motor i needed a new intake manifold, mine was cracked pretty good. could not find one, so i took a boyesen rad valve, re shaped to make right.
before, oem 86 on left, 87-04 rad valve on right
(http://inlinethumb58.webshots.com/42489/2836066080035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2836066080035658722DUGSDo)
i had to flip the reed cage once the bend was cut off, then massage on inside a littlle more to get it to line up where the old one was. all welded up and good now. in the end the rad valve is a clamps width longer than oe, but my new carb is that much shorter than the old mikuni, so all is well
(http://inlinethumb27.webshots.com/1818/2236132330035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2236132330035658722qSjxUK)
about the only good parts on my motor were the powervalves. when i went thru the engine, i moly coated the outside of drums, and used slik ceramic in exhaust port/ powervalves
(http://inlinethumb24.webshots.com/9687/2594918600035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2594918600035658722pCcgSN)
cylinder got leaned on pretty good, ought to run pretty right
(http://inlinethumb10.webshots.com/45257/2143365450035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2143365450035658722NHmtqC)
bike had a sleeve, needed a bore. piston got moly on skirt, ceramic up top.
(http://inlinethumb01.webshots.com/48192/2733681910035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2733681910035658722ebndMl)
completed engine
(http://inlinethumb35.webshots.com/43234/2763038500035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2763038500035658722aNgpmC)
the head on this bike was pretty warped. cut a bunch off to make right. reshaped the dome, etc etc. had a compression release put on it. also made adjustable stop to make the powervalves right
(http://inlinethumb21.webshots.com/46996/2086440750035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2086440750035658722kPTLGa)
rad valve incognito
(http://inlinethumb41.webshots.com/41448/2323824270035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2323824270035658722IgPHTL)
i plan on putting motor in tomorrow, hope to race it this coming saturday.
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Looking great so far, wow!
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Wow... Get a good deal on coatings??
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that's going to be sweet.
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Excellent work! It's gonna look sweet when done.
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wow thats awesome :-D :-D
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Wow! That looks so badass, Byron. I'm the one that sold you that bike and i can assure people, you were kind in your assessment of it. That was the first bike I ever bought and it was pretty jacked when I got it. I can't wait to see what it looks like when you are done.
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thanks guys, it didn't mean to put this much effort into it originally. but it should be a nice old kx when i am done.
iamsofaking, i actually think i still have your email, was going to see about going riding sometime. you still have your newer kx?
motorrad, i do all this coating stuff myself at my buddies place. he has oven that we do just that with. i do the prep, he sprays and bakes.
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Thanks for saving this bike! I had one and it was one of my favorite bikes ever. Paid $3k for it in the crate :wink:
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WHAT DID YOU USE TO CLEAN UP THE FUEL TANK THATS LOOKS FRESH NOW ?
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BacK.IN.THE.DaY, i used a 3m headlight repair kit. very teadiuos, but as you can see it paid off. that tank looked worse than what i had, had alot of oxidation.
got a little done on the bike today.
a few pics
about a year ago after all the fixing i powdercoated frame the oe color
(http://inlinethumb61.webshots.com/30588/2235372090035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2235372090035658722QlcflQ)
took alot of work to fix. the lower mounts were gone, the side panel front mounts on both sides were broken, the upper pipe mount broken, frame tube was worn/ cracked from chain rubbing, bottom right corner of frame cracked, front seat hold down tab broken. also hacked off the kickstand mount
(http://inlinethumb05.webshots.com/24516/2877614830035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2877614830035658722NrnNMa)
(http://inlinethumb32.webshots.com/44895/2164676800035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2164676800035658722rJBqCw)
(http://inlinethumb27.webshots.com/46938/2858044530035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2858044530035658722OYEmkv)
the lower shock mounts needed alot of work also, from the motor flopping around it basically wore about 1/8 off each mount were it rides next to motor. each case had about same worn off as well. lots of welding/ machining.
so after that powder coated the shock mounts and upper shock mount as well
(http://inlinethumb08.webshots.com/9031/2900992470035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2900992470035658722ngIEZG)
my swingarm was hammered, the bearings were shot, from the chain flying off all the time or being loose it ate the swingarm to the point it was almost worn thru in a few spots. surprisingly though the front upper/ lower slider was perfect.
about a year and ahalf ago while looking on ebay for some junk i found 2 nos 86 500 swingarms. i picked up both for 50 with shipping. my 85 kx125 has a 86 250/500 disc brake rear, so i got 2 swingarms that were brand new!
(http://inlinethumb10.webshots.com/45193/2740352740035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2740352740035658722WVETrR)
(http://inlinethumb29.webshots.com/47772/2179781580035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2179781580035658722bVeWwR)
as far as brakes go, i have never liked the 88 down kawi calipers. when i was a kid i always had pad issues. i'm sure there were other things wrong, but i remember always jacking with them. this bike runs same caliper front/ rear. for the rear i am running a 87-01 honda caliper, or basically same as 95 up kawasaki. my 86 wheel was shot, typical 86 rim cracked in like 50 spots, spokes rusted/ frozen/ broken, hub cracked at sprocket mount, left bearing holder part cracked, rotor dead. i also am not a fan of the steel wheel collars, and the fact that the 86-87 rotor was a funny bolt pattern that it seems noone makes anymore. a 89-01 cr500/ 89-99 cr250/ 89-99 cr125 hub bolts right on. nice thing is has better wheel collars, rotors are plentiful, hubs look like old works kx stuff. the kx and older crs had same 220mm rotor. 86-87 kx had 190mm rotor. 97 up crs have 240mm rear rotor. 97-99 had the 240, but used the smaller axle, just like this 86. so i am using a honda rear wheel with a 240mm rotor from 97-11 honda. since i wanted to use newer cr/ kx caliper i needed to change the caliper mount guide.
here is the oe
(http://inlinethumb04.webshots.com/37059/2680526460035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2680526460035658722CjiaXk)
a 95 up kx or 87 up cr have almost identical calipers/ mounts. only real difference is kawi mount has no disc guard mount, and on outboard side the pass thru for axle is about 1/4" wider.
so i took a caliper mount guide and welded on this 86 arm/
mocked up, needed to space it in 1/4 due to using the honda hub
(http://inlinethumb22.webshots.com/20245/2662106530035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2662106530035658722WkBKTc)
all welded up
(http://inlinethumb46.webshots.com/42861/2140994110035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2140994110035658722TmxRwo)
i put the motor in, and put suspension on. the bike needed all new bearings in everything, so did all that. the shock got new lower bushing/ upper bearing, strut/ linkage, swingarm, stem. this bike also will use a 46mm front end from 89 kx.
my shop is so packed i have no room to build this bike. basically being assembled on plastic fold out table. pretty ghetto
(http://inlinethumb34.webshots.com/46113/2174735810035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2174735810035658722rxFeav)
tank isn't mounted
the seal savers work, but sure do look stupid. i wish i could find those old plastic covers i used to have.
i originally rebuilt the suspension myself, but later sent out to mx tech to make the valving right.
(http://inlinethumb25.webshots.com/41560/2153282720035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2153282720035658722SfYJmw)
46mm kayabas
(http://inlinethumb58.webshots.com/47097/2636698830035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2636698830035658722ZJRhcS)
i have noticed a few problems today.
first, not too big a deal but i always use sunline shifters. they make a nice part. i bought the one for kx125/250/500, but went to mount today and the shifter has bigger hole than the shift shaft. i checked my later kx motors and they were the same as the 86.
2nd, i have had a few 46mm front ends laying around for 6 or 7 years. planned on installing on my 85 kx125. about 4 years ago i found a few braking 260mm oversize rotor setups for 89 up kawi. the bolt spacing on new caliper bracket was 100mm. rotor mounted to my 89 wheel fine. went to mount caliper today and noticed the 89 fork has a smaller bolt spacing than 100mm. it is like 78mm or something. all these years and i never thought to double check until today when i finally decide to mount it up. had i of know, when forks apart would have welded new tab. haven't looked to hard but i can probably figure it out. this 260mm rotor setup will be on this bike one way or other!!
last problem, kinda big, with tank on bike you can't turn the forks to stops. the top triple clamp hits the tank before the lower clamp hits the stop. when the clamp hits tank, i have about 3/16-1/4 gap between lower clamp and stop. i thought at first it was the 250 tank i am using, but in that part of tank the 250/500 tanks are identical. i thought i measured the fork offset, i haven't double checked but i thought it was same as oe 86.
it kinda sucks, i can just weld up the stop on frame, but not sure how many degrees less steering i would have either way. maybe i can notch the upper clamp, it does have a ton of meat in that area, but that sounds little sketchy. if i was good at plastic welding it would be easy to trim the tank a little. but the times i have tried to plastic weld i failed terribly. tomorrow will look at everything harder. i saw that at end of work today.
another small thing that is fixed now is that i bought a later style clutch cable for it. turns out the 86 had small pilot on case that clutch cable sits in. the later motors were bigger. so at first the newer cable would not work. so i just drilled the pilot out to the size of late model. have nos old terrycable cable that fits perfect now.
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Great progress. Coming along very nicely. Good job.
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Great thread. I have a complete front end off an 89, maybe I'll keep it for future use!
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Hey Ron The bike looks Grreat!
You surely have done this kind of resto work before. I think I would be too afraid to ride a bike with that much TLC involved...
You are the only other person I know of that drilled/slotted the oem clutch basket. Most guys who opt for the open basket buy a billet piece already done.
I don't have the tools to cut out the slots, so I just drill two holes in place of the slots.
I have drilled five different baskets on various machines with no ill effect...Yet!
I also like the use of the engine coatings. There is a coating for just about all the engine parts now, it's just a matter of how much a guy can afford.
The piston has a different "window(s)" than I'm used to seeing, is that KawRiders design?
Here's what mine looks like.
(http://i69.photobucket.com/albums/i75/Friar-Tuck/Misc%20Stuff/th_DSCN1847640x480.jpg) (http://s69.photobucket.com/albums/i75/Friar-Tuck/Misc%20Stuff/?action=view¤t=DSCN1847640x480.jpg)
(http://i69.photobucket.com/albums/i75/Friar-Tuck/Misc%20Stuff/th_DSCN1845640x480.jpg) (http://s69.photobucket.com/albums/i75/Friar-Tuck/Misc%20Stuff/?action=view¤t=DSCN1845640x480.jpg)
Top, side and oil dispersant underneath, I hope the underside wasn't a mistake. I may be retaining heat, I guess I'll find out!
Tuck\o/
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Bike is looking great. im getting jealous :-D. I have a 87 k5 im slowly rebuilding/restoring. i will post pics when i eventually get my self in gear.
Thanks for the plastics cleaning/polishing advice to.
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tuck the holes on the back of piston have to do with the porting.
i have done some more to the bike, but it is not finished. been busy at work this week, not much time, also bad weather slowed me down.
some progress
mounted footpegs, used oem hardware
(http://inlinethumb57.webshots.com/46200/2183552540035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2183552540035658722WABWYD)
exhaust mounted
(http://inlinethumb55.webshots.com/45878/2549944320035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2549944320035658722BpcOXq)
(http://inlinethumb25.webshots.com/44632/2677790980035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2677790980035658722EAuBeZ)
as mentioned i am using a honda rear wheel, but didn't have one built laying around. i had all the parts, so laced a wheel up last night. once mounted built the rear brake, bled, etc. if anyone cares, i can elaborate on what it takes to mount a honda rear wheel.
(http://inlinethumb34.webshots.com/36705/2618015050035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2618015050035658722AFUveT)
(http://inlinethumb55.webshots.com/3510/2548323020035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2548323020035658722sTuVYZ)
used a 88 up rear pedal. little bit longer than oem 86-87. used honda master/ caliper/ line, 240mm rotor
(http://inlinethumb13.webshots.com/44172/2913149730035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2913149730035658722ZMjsWj)
trimmed off the oem honda caliper guard brackets, left the oem kawi bracket. looks pretty normal i think.
on the front brake issue, i found that the bolt spacing on 89 forks are same as 04 up honda. problem is the caliper is located in a different spot on fork tube than honda. so honda bracket will bolt up, but not work. since i am using a 260mm front rotor i tried a 04 up 260mm rotor bracket for honda, was worse. here is what the oem 240mm honda bracket looks like where it needs to be
(http://inlinethumb49.webshots.com/45168/2041516950035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2041516950035658722ZdUzWm)
you can see the lower mount needs to be fixed. i made a tab to mount it up. it will work perfect.
i was getting anxious, so i mounted the fuel tank, and installed a carb.. using a pwk off a late 90s cr250 or kx250. bike fired almost right up, everything sounded fine. no clatter from powervalves or anything. after a minute or so of running i noticed the rear of head was leaking water. i bought a athena gasket kit, but regardless the gasket was leaking to the outside. i let it run a little more, shut off, re tourqed head, started back up and seems fine. we'll see i guess. i really didn't like how the head mounted. it doesn't seem to center up well. i remember i just squared everything up. would be a good thing in future to pin it or dowel or something.
i put on the right sidepanel and stuck the seat on.
(http://inlinethumb25.webshots.com/48152/2549849820035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2549849820035658722CTEovH)
i have a tall foam mounted on a reproduction cover. the radiator shroud is just hanging there, looks pretty tweaked. junk maier stuff.
didn't plan on using yellow carb vent lines, all i had a laying around.
looking at the pic it brings back some good memories, been a while since i had an old kawasaki around.
on my steering issue, i ended up taking a hair of material of each side of upper clamp, then welded up stop on either side on frame. i lost about 2-3 degrees sweep each way. the upper clamp is solid where i removed a little, shouldn't affect a thing.
am little bummed about the head. hopefully re tourqing it did the trick. think i will need to end up removing though. would prefer all metal gasket. cometic makes a gasket kit for top end, maybe theres' is like a late model. i tried my compression release also, didn't seem to do anything much . need to put a guage on it. was really wanted to race a kx tomorrow, but one more week isn't going to matter.
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Looks really nice!
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That is all kinds of sex. Excellent job.
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Brings a tear to my eye....I loved that bike. One of the best out of 20 some bikes Ive owned! Thanks for the thread.
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that seat foam looks absolutely ridiculous
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that seat foam looks absolutely ridiculous
You must be "Vertically Challenged" :lol:
DoldGuy
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that seat foam looks absolutely ridiculous
You must be "Vertically Challenged" :lol:
DoldGuy
nope
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that seat foam looks absolutely ridiculous
You must be "Vertically Challenged" :lol:
DoldGuy
nope
Okay then, just challenged :lol:
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that seat foam looks absolutely ridiculous
You must be "Vertically Challenged" :lol:
DoldGuy
nope
Okay then, just challenged :lol:
naaa. i think the seat looks like a box. lololololololol
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when i built that seat a year or so ago i didn't like the height it ended up, looked weird to me as well. but after installing it the other day, with my lowered pegs the bike feels perfect. i am 6 ft 5 and most any old bike except a ktm seems to be made a for a person a ft shorter than me. the seat to peg height is where i want it. in person it looks more normal, but still kind of a hoss. as long as it works for me i don't care really how it looks.
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That's the way it should be.
It's like my Grand pappy use to say, "I don't care if you play the trumpet through your nose as long as it sounds good".
So, it does not matter how it looks as long as it performs good for you.
Good job.
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more or less finished the bike today. need to bolt on the skidplate, brake snake, and mount some old decals i had reproduced.
i had a spare shift shaft for my 94, turns out 94 up have bigger spline. was able to bolt up my nice shifter afterwards.
re sealed the airboot, cut out a pc racing pro seal to help seal the filter
(http://inlinethumb54.webshots.com/39157/2320956090035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2320956090035658722rbDASl)
put a fresh twin air on, cover and it was done
(http://inlinethumb27.webshots.com/45466/2580094230035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2580094230035658722lOABSY)
right side
(http://inlinethumb03.webshots.com/45250/2924128180035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2924128180035658722aepfel)
front, need to mount handguard sheilds
(http://inlinethumb27.webshots.com/30682/2436648570035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2436648570035658722QyNITs)
(http://inlinethumb36.webshots.com/15715/2707584640035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2707584640035658722kMEbTl)
motor left side
(http://inlinethumb20.webshots.com/42387/2426617770035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2426617770035658722XDiXDC)
front wheel, front caliper/ master/ hose from honda, you can see lower mount bracket i had to make, 260mm rotor
(http://inlinethumb28.webshots.com/13851/2993163440035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2993163440035658722tKcfnE)
controls, i need a new kill switch. i went to tighten the strap, housing broke. throttle from late model kx
(http://inlinethumb17.webshots.com/46736/2580561780035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2580561780035658722kUHIex)
motor right side
(http://inlinethumb58.webshots.com/48121/2877652380035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2877652380035658722mogxaX)
oe louvers were black, but used 88 up radiators, so went green
(http://inlinethumb43.webshots.com/38826/2584099500035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2584099500035658722YuKwtY)
best part
(http://inlinethumb17.webshots.com/42576/2457556570035658722S500x500Q85.jpg) (http://rides.webshots.com/photo/2457556570035658722SlZlnJ)
i always liked those decals. behind shroud you can see beefed up pipe mount
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for the longest time i have been looking for a backwards keihin for my 85 125 and this 86. i knew that tuning this with normal carb would be tedious. i managed to find a right side adjust 35mm pwk for my 125, but never anything for this 500. so now to adjust air screw and idle the airbox needs to be off. but with no airbox it is not the same. i think i will buy like a uni sock filter to help. but i did get it in the ball park. the needle feels lean, but overall ok.
i rode it for about 30 min total today, it is a pretty smooth motor. sitting on stand when you rev it things vibrate, but not much. once your'e on the bike and riding it feels fine. the crank work definatly is worth the $$.
i haven't been on a kx in a long time, used to all my hondas now. but this bike feels fine for me. the tall seat, lowered pegs, rc high bars, tall mounts make everything fit perfect. it seems to shift fine, but the clutch is dragging a little. i had a nos ebc clutch kit i used. will ride some more before taking back apart.
the bike feels light, seems pretty stable. broke the brake pads in, everything works well. head hasn't leaked again yet. the powervlaves are nice and quiet. the weather around here has been all over the place, may be a day or so before i can ride it again. hoping i can make the jetting right without too much more fuss.
i would have liked to put the oem 500 decals on, but the maier sidepanels i bought had louvers like a 88 up right where decal goes. i have since found a company that makes exact replica sidepanels. might one day invest in those.
i have another old bike race in a few weeks. hope to have all the bugs worked out for it.
it's nice to be on a green bike again. i grew up riding 80's kxs, must have had 10-12 or so though the years, this bike brings back lots of memories. i'll admit it took me about 30 minutes to shut the door on it today, was just sitting there looking at it.
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AMAZING!!! that bike was scrap metal before the resto.
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I can't believe how gorgeous that thing is.
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That is one beautiful K5. Very well done.
I'll dig around for a kill switch. I know I have a couple. PM me your address and I'll ship it out asap.
I didn't put mine back on my K5. I bought a White Brothers tether switch.
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Hi. Your K5 looks Sick now and to think this was basicaly a pile of scrap :-o
good job keep up the good work.
also if you no were to get the kips engine/motor Badge/decal from it would be a great help
as i need one for my 87 K5 engine.
I am rebuilding/restoring my 87 K5 slowley but surley id be happy if it looks half as good as your 86 :wink:
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thanks guys, it was a little more work than i planned, but i think worth it. always wanted a nice 80's kx500. once i get the jetting and clutch right it will be fun to ride. the weather around here is supposed to be nicer next few days, hopefully will have time to ride some more.
i need to put a guage on this motor. i think it makes more pop than i think. my compression release works, but does nothing to ease the kicker.
BacK.IN.THE.DaY, my kips emblem was on my cylinder already. i would assume it is glued on, but my jug was baked in oven for a while. it never fell off. i would not know where to get one.
i had a few 87 125s, always liked those bikes. you can still get all the plastic from ufo for yours. much better than the maier crap. i have a mint rear wheel/ rotor/ tire if you need.
i just recently bought a helmet camera, but haven't had time to fool with it. if i can figure it out i'll load a video of the thing riding around. definalty taking this to my next race.
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nice project.....
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are you going to make a youtube video of it running and riding? :?
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i don't know anything about you tube. i bought a contour hd camera, i think they have a site you load the stuff at, then just copy/ paste link. i got the jetting much better, but the clutch is still dragging. need to double check a few things.