KX Riders
Maintenance & Technical => KX500 Original => Topic started by: greylynn on May 02, 2011, 06:26:37 PM
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I did a partial trade on this 2003 KX500 and wanted to do a few mods. I haven't checked the compression yet, but it seems ok by the feel of the kicker. I'll check it this weekend when I get the tank and stuff off. Some of the mods to come are IMS pegs, Plastics, V Force Reeds, complete wheel set up for dunes, rotors, Paddle, torque spacer, grips, and a bunch of OEM stuff to tighten it up.
Anyway, I always wanted to do a progress build and post pics of the transformation. So here is what it looks like right after I bought it. (After I removed all the stickers).
And please excuse the mess in my garage, I just moved :-D
Grey
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00433.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00432.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00431.jpg)
Here is after I started removing a few things. These things including the kickstand which I haven't removed yet will be in the for sale section after I hit 10 posts.
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00439.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00449.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00447.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00443.jpg)
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Ill be watching...
That kickstand is the best thing since sliced bread.... may want to reconsider keeping it.. I just had to shell $150 for one... and Now that I have it.. Id gladly shell more than that.
EDIT:
Hmm.. Odd.. just noticed you have a RED STICKER.... That shouldnt be... should be a green stickered bike..
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02 and older are green and 03 and up are red.
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+1 on the kickstand.
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That bike will love you long time. :-D
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Looks like it's already done!
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Yeah, it pretty much was already done, but I can't leave anything stock lol. It's stripped down to the frame almost now. I have to find a way to get that top exhaust mount welded.......There are a ton of parts on the way..I'll post pics.
Grey
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Yeah, it pretty much was already done, but I can't leave anything stock lol. It's stripped down to the frame almost now. I have to find a way to get that top exhaust mount welded.......There are a ton of parts on the way..I'll post pics.
Grey
IMO, don't loose sleep over the broken exhaust mount. It's a common issue with the KX500's. Mine was broken when I bought my bike back in '05, it's still broke today. There is no need for 3 mounts IMO, but if it really bothers you than have a new mount welded...
FYI, have a GOOD look at the inside of your subframe on the drive chain side, it should be all gouged from the drive chain. This is an issue you need to address. Many of us rivet a piece of sheetmatal or plastic on the inside of the subframe to act as a buffer from the chain. I have a bunch of 1"X6" teflon strips that work the balls PM me your mailing address and i'll maile you one.
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Yeah, it pretty much was already done, but I can't leave anything stock lol. It's stripped down to the frame almost now. I have to find a way to get that top exhaust mount welded.......There are a ton of parts on the way..I'll post pics.
Grey
IMO, don't loose sleep over the broken exhaust mount. It's a common issue with the KX500's. Mine was broken when I bought my bike back in '05, it's still broke today. There is no need for 3 mounts IMO, but if it really bothers you than have a new mount welded...
FYI, have a GOOD look at the inside of your subframe on the drive chain side, it should be all gouged from the drive chain. This is an issue you need to address. Many of us rivet a piece of sheetmatal or plastic on the inside of the subframe to act as a buffer from the chain. I have a bunch of 1"X6" teflon strips that work the balls PM me your mailing address and i'll maile you one.
Thanks for the info, I really don't want to pay out the rear to fix the weld, I'll have to see how much it will cost me. I didn't see any gouging on my subframe, can you post pics of where you are talking about?
Grey
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Yeah, it pretty much was already done, but I can't leave anything stock lol. It's stripped down to the frame almost now. I have to find a way to get that top exhaust mount welded.......There are a ton of parts on the way..I'll post pics.
Grey
IMO, don't loose sleep over the broken exhaust mount. It's a common issue with the KX500's. Mine was broken when I bought my bike back in '05, it's still broke today. There is no need for 3 mounts IMO, but if it really bothers you than have a new mount welded...
FYI, have a GOOD look at the inside of your subframe on the drive chain side, it should be all gouged from the drive chain. This is an issue you need to address. Many of us rivet a piece of sheetmatal or plastic on the inside of the subframe to act as a buffer from the chain. I have a bunch of 1"X6" teflon strips that work the balls PM me your mailing address and i'll maile you one.
Thanks for the info, I really don't want to pay out the rear to fix the weld, I'll have to see how much it will cost me. I didn't see any gouging on my subframe, can you post pics of where you are talking about?
Grey
I archived my post years ago that showed my mod but the imageshack pics are no good anymore. I'll try to find the pics in my computer. Here's another post I found:
http://www.kxriders.com/forums/index.php/topic,2492.0.html
http://www.kxriders.com/forums/index.php/topic,1533.0.html
Here's some really great tips :
http://www.kxriders.com/forums/index.php/topic,434.0.html
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I Use a piece of stainless bent at a 90Deg Rivited on to mine...
As it looks good... (Im alittle wierd when it comes to looks..).
stainles gets HARDER the more its rubbed on by the chain too... (anyone who has drilled stainless knows how this works)
Those are extra holes drilled in the stainless only... I put them in there incase I needed them later...
(http://i13.photobucket.com/albums/a289/Motorrad/DSC_5827.jpg)
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I'm tempted to just leave the mount on top broken, but I just don't like the idea......Hard to find a welder in my location that won't rip me off.
Grey
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I'm tempted to just leave the mount on top broken, but I just don't like the idea......Hard to find a welder in my location that won't rip me off.
Grey
Id weld it for free if you were in my area. :roll:
If you find the right guy. they will weld somthing that easy for lunch or a case of beer.. Just make sure you take the CDI off the bike before you take it to get welded...
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I'm tempted to just leave the mount on top broken, but I just don't like the idea......Hard to find a welder in my location that won't rip me off.
Grey
Id weld it for free if you were in my area. :roll:
If you find the right guy. they will weld somthing that easy for lunch or a case of beer.. Just make sure you take the CDI off the bike before you take it to get welded...
Thanks for the offer! I took it to a place in town, gonna be $35 with the nut welded on the back, and beefed up so he says. While it's stripped down is the time to do it anyway. I don't think I would have lost sleep, but I would have tossed and turned lol I'll post pics tonight.....
Grey
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I like that guard for sub frame. I need to do that to mine. I'd keep that kickstand if I were you. But If you are selling it I might be interested.
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If someone were to start making a rub protector I would surely buy one just in case someone out there is feeling ambitious :) too bad the aftermarket subframe maker doesn't add one onto the K5 subframe for those who buy them it would be a nice addition or selling point to have something with a replaceable runner for the spot the chain rubs at.
Since I raced my bikes since I was 8 years old I had to learn to do a lot of things on the bikes but always paid to have the internal work done or stripping the bikes so hats off to you for being able to take the bike down and do your own work I should have taken the plunge but was skeered.
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Get yourself a piece of 5/8 heater hose split it down the middle and zip tie it on. Simple, cheap, easily replaceable.
serafin
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Get yourself a piece of 5/8 heater hose split it down the middle and zip tie it on. Simple, cheap, easily replaceable.
serafin
I did that last trip out... because I had issues with my stainless one (I was an idiot and put it on backwards so the chain caught the edge and pulled it off)...
It was eaten half way through within 2gal of fuel... (the rubber heater hose)
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The kickstand is nice, I have the same one. But if the bike is running, it will walk itself pretty bad so be carefull! Really, it is just there to prop it up when it's not running. Like when you go back to the truck to smoke a butt and drink a beer. Makes it look cool. And it beats leaning it against a tree out in the woods! Or dragging the "dinner bell triangle" stand around with you!
And I was gonna say that welding the mount is like a 5 min. welding job. I cant see how it could cost more than 30 bucks. I will have to get a rub gaurd on my subframe too, it's chewed up pretty bad.
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Ok, I'll keep the kickstand lol. If you look at the pic below you can see where the kickstand wore on the side plate. I don't know if the guy didn't realize it went behind the plate, but it was on the outside rubbing the plate.......I'll investigate this weekend....It felt a little loose.
Anyway, I got some parts today, the VForce reeds look Frappin' sweet!
I also got the exhaust mount welded and the nut welded to the back of it. I thought the guy did a pretty good job and even painted it for me. See pics. I'll get more parts in Friday and get to putting this thing back together a little on the weekend. I ordered a Pro Circuit Platinum 2, I had the Works pipe and the Platinum 2 on my CR500 and I liked them. I think they feel a little more on the pipe if you will than the FMF. This thing is going to be for top end in the dunes anyway. I also think the FMF Turbine Core silencer is not appealing to my eyes. So the FMF will be for sale. The black plastics should be here too.
Grey
Exhaust mount
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00451.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00450.jpg)
Kickstand rubbing on plate
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00446.jpg)
Some new Parts
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00454.jpg)
What the bike looks like now
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00457.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00456.jpg)
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Not sure about Dumont... but they are checking spark arrestors VERY AGGRESSIVLY here in my neck of california... just a FYI...
Interesting rub mark.... since the kick stand is supposed to tuck BEHIND the number plate... not infront of it... Somthing isnt right..
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Not sure about Dumont... but they are checking spark arrestors VERY AGGRESSIVLY here in my neck of california... just a FYI...
Interesting rub mark.... since the kick stand is supposed to tuck BEHIND the number plate... not infront of it... Somthing isnt right..
I only ride at Sand MTN NV, so I ordered the 304 silencer. The bike is kinda a side project, I have a turbo Raptor and a TRX450R that I take to the dunes. This bike probably will only get ridden once or twice a trip. I can't ride all three at the same time lol. Don't get me wrong, I started on bikes and always wanted a K5, so we'll see what happens, maybe I'll go back to my roots.
I agree the stand is funky, I'll check it out this weekend....He might have just left it in the front for some reason.
Grey
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Not sure about Dumont... but they are checking spark arrestors VERY AGGRESSIVLY here in my neck of california... just a FYI...
Interesting rub mark.... since the kick stand is supposed to tuck BEHIND the number plate... not infront of it... Somthing isnt right..
I only ride at Sand MTN NV, so I ordered the 304 silencer. The bike is kinda a side project, I have a turbo Raptor and a TRX450R that I take to the dunes. This bike probably will only get ridden once or twice a trip. I can't ride all three at the same time lol. Don't get me wrong, I started on bikes and always wanted a K5, so we'll see what happens, maybe I'll go back to my roots.
I agree the stand is funky, I'll check it out this weekend....He might have just left it in the front for some reason.
Grey
Cool.. just making sure on the pipe...
Trust me Im in the same boat as you on bikes... when I go out . (even for a week)... I normaly have a differant bike to ride every single day.. sometimes more.. :roll:
here is how the kickstand should fit BTW
http://www.kxriders.com/forums/index.php/topic,2018.0.html
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Get yourself a piece of 5/8 heater hose split it down the middle and zip tie it on. Simple, cheap, easily replaceable.
serafin
Thanks and I'm surprised someone or some company hasn't made something dedicated for this purpose with replaceable delrin blocks or something and in the weapon industry someone is always trying to make some useless gadget for the fish to buy and the AR guys will buy anything and everything lol but this would actually be something useful so just a little surprised someone hasn't come up with a slick unit like BRP perhaps.
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Get yourself a piece of 5/8 heater hose split it down the middle and zip tie it on. Simple, cheap, easily replaceable.
serafin
I did that last trip out... because I had issues with my stainless one (I was an idiot and put it on backwards so the chain caught the edge and pulled it off)...
It was eaten half way through within 2gal of fuel... (the rubber heater hose)
That's why I fabbed mine out of Teflon. I also put a small chamfer so the chain easily rubs past the teflon with no issues. Like I said, I have a bunch of them if you want one pm me your address..
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I got the moose Torque spacer and the V-force reeds installed. I had to cut the tabs off the intake boot, but other than that pretty easy. The intake/air filter boot on the opposite side of the pic is kinda sunk in because of the tweaking of the fit. This set up barely fits now and the intake shape has now changed....Think this will affect performance negatively?
I bought a brand new intake boot because the old one had some minor cracks in it that I didn't want to become major and the new one has a few tiny little cracks in it, I guess it's just kinda unavoidable with rubber. None of the cracks go all the way through of course.
I got all the plastics, sprockets, exhaust o-rings, new fuel lines, rotor and sprocket bolts for the completely seperate dune Excel wheels which should be here next week, and a bunch of other stuff in. I'm waiting for the wheels to get here before I put that stuff on so I don't have to remove anythingg else. Anyway here are a few pics. By next weekend I should have major progress....
Grey
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00459.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00458.jpg)
I had to get this sprocket because the wheels are going to have gold hubs, black spokes, black rims and gold nipples. And the new chain is gold, so I thought it would look pretty!
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00460.jpg)
It's going to have black front and rear fenders, green side and front number plates with black fork sliders.
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00464.jpg)
There are a lot of other things on the way, Devol radiator guards, I think I want to make those black, new chain slider and rollers, Tm Designs flag holder, Pro Circuit Platinum 2 pipe and 304 silencer, and other stuff I can't think of right now lol, let me know what you guys think so far :)
Grey
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WOW goin all out! :lol: It's hard not to with the K5 isin't it! Just want it to look mint, even though it's gonna get covered in dirt! But the dunes are different than riding in the woods and mud like I do! :-D
Looks like you have the carb. pushed too far into the intake boot in that pic. I would not let that stay that way.... I have the tourqe spacer on my build too.... So I will have to look into modding the airbox mounts to bring it back like a 1/2" So that the airbox boot is not deformed and the carb. is not shoved too far into the intake boot also. I would monkey with that a little more if I were you. just a suggestion. :-)
The weld work on the mount is good work too, he did do a good job.
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WOW goin all out! :lol: It's hard not to with the K5 isin't it! Just want it to look mint, even though it's gonna get covered in dirt! But the dunes are different than riding in the woods and mud like I do! :-D
Looks like you have the carb. pushed too far into the intake boot in that pic. I would not let that stay that way.... I have the tourqe spacer on my build too.... So I will have to look into modding the airbox mounts to bring it back like a 1/2" So that the airbox boot is not deformed and the carb. is not shoved too far into the intake boot also. I would monkey with that a little more if I were you. just a suggestion. :-)
The weld work on the mount is good work too, he did do a good job.
Thanks for the compliments, I'm going to figure something out to stop the deformed boot from happening, thanks for the imputs!
Grey
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Well I checked the compression when I had a minute, It was 160PSI spot on everytime. When I took this pic I got off the bike and went to get the camera so it leaked a lil off. I think I am right where I should be 105-164 psi correct? The guy I got the bike from said it was barely ridden....He was going to make it a hillclimber, but never did.
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00479.jpg)
I decided to also polish the swingarm with the brushed aluminum style look that Motorrad showed in a thread somewhere. I'll post some pics once I get a little further on that project.
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00482.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00481.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00483.jpg)
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160 psi is perfect. That signifies a strong top end. Anything less than 140 and your loosing power.
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Well, I got my graphics on, and the swingarm polished to about where I want it. I didn't want it mirror finish, and even if I did I don't have that kinda time lol. Came out good enough for me. I also don't like the gas tank graphics at all, so those will stay off. The silencer came in and looks really long! geez! The pipe should be here Friday along with the Rims. I put on a new OEM chain slider and I have new rollers to install. I have some ASV levers on the way, then get the tires put on the rims on Sat. Anyway still lots to do, here are some pics.
I'm trying to find black number plate backgrounds to install, but no luck. Rocky Mountain ATV has a cool attack custom thing you can order, but only for OEM plastics, they said it won't work on UFO plastics......
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00570.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00568.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00566.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00565.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00572.jpg)
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The part about working on OEM and not UFO plastics makes no sense to me. They're the same.
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I just talked to Decal works and they said the same thing. My OEM plastics look exactly the same. I think I'll just order them from RMATV....
Grey
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I think I'm going to take the Moose reed spacer out. Since this will be a duner, I want it to hit hard, and I want top end....Since I haven't even ridden the bike yet, I will have no idea if there is any difference. I think I will take it out and when I get to the dunes ride it normal, then put the spacer in and ride it again.....Any inputs?
Grey
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I think I would leave it in. If I understand the theory for the spacer correctly, leaving it in will atomize the gas better. I ran my 250 without one, just figured it was a gimmic like the "roost boost" of the 80's. I came across one dirt cheep and brand new, threw it in the 97 KX250 and took her out on the track. NIGHT & DAY, smoother and quicker response. Corners that I had to feather the clutch through, she now pulls strong with no sore fingers. I have every intention of droping one in the Juggernaut. :-o
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I got the wheels and got the tires put on them. I think they look sweet! They have +1 oversized spokes on them too. With a 49 tooth sprocket on the axle all the way back and a 120 link chain cut down to a 116 I think, the chain is tight. I think it's going to stretch and be alright though. On my CR 500 i had to drop a tooth on the sprocket to get the 5.60 Cheng Shin to fit. It's gonna be fine I hope. If not, I'll have to go down a tooth, hopefully that will work. I gpot the Pro Circuit Platinum pipe on too, it's not the platinum 2 just the regular platinum, here are some pics....
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00574.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00575.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00576.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00577.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00579.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00578.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00580.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00581.jpg)
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I also have light speed carbon fiber fork protectors on the way along with some black number plate backgrounds. That should finish it off. The stupid Wheeler Whips flag holder I got doesn't fit and It's for tiny little 1/4 in flags, so I have to send it back.
Grey
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Dam, I would LOVE to try a "dune" KX500 ! I've ridden many times in sand, but nothing like out in the wide open dunes.... Bike looks trick !
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Nice bike! 8-)
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Thanks for the compliments! I got some Works Connection frame guards, Light Speed Carbon Fiber fork protectors, ASV F3 levers and a Billet kill switch to replace the Pro Design racing tether switch. Here are some pics. My number plate backgrounds should be here this week too.
Light Speed Fork Guards
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00582.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00583.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00584.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00585.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00586.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00587.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00588.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00589.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00590.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00591.jpg)
Billet Kill switch not installed yet.
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/2003%20KX500/DSC00592.jpg)
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I got the Number plate backgrounds and put those on. I really like them! Also if anyone orders the Attack graphics number plate backgrounds or graphics from Rocky Mountain ATV, the graphics application kit is awesome. It's just some spray and a 3M squegee, but it worked extremely well when I put these number plate backgrounds. I also got a Works Connection rear brake guard. here are some pics. In the first one it appears they aren't on well, but the bottom curves out so it's a reflection, and I fixed the top. Had a little extra application fluid not pressed out.
Grey
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/DSC00593.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/DSC00594.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/DSC00595.jpg)
(http://i209.photobucket.com/albums/bb184/milesdeweydavis/DSC00596.jpg)
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Very nice!
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I personally don't buy into the bling thing, but I gotta' give credit where credit is due, and your 500 looks really trick ! nice job ! The saddest day of your life will be the day you bring your freshly blinged out KX500 home from a muddy ride... (or the first low side crash) :roll:
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I personally don't buy into the bling thing, but I gotta' give credit where credit is due, and your 500 looks really trick ! nice job ! The saddest day of your life will be the day you bring your freshly blinged out KX500 home from a muddy ride... (or the first low side crash) :roll:
Thanks, I don't think it is that "blinged out" but I'll take the compliment. And I have no problem getting it dirty, that's why I take pics lol. The same thing happened to my turbo Raptor, looked pretty, not so much now, but I can still remember! And it will still look good, wear and dirt just adds character!