Recent Posts

[imghttp://[/img]

1989 kx500, not gonna saw it half

Have you put the bike on a stand, spun the wheel, and watched the brake rotor?

yea, rotor is good....today I robbed the front brake assembly off my 96kx250 and put that on the 98...pulled everything back apart, mc and caliper reinspected, cleaned and installed on the 96 everything looked good and seemingly worked fine...took the bikes out this fternoon and same thing happened within 20 mins!! So ima frustrated!

What brake fluid are you using and what material type are the seals?

Have you put the bike on a stand, spun the wheel, and watched the brake rotor?

yea, rotor is good....today I robbed the front brake assembly off my 96kx250 and put that on the 98...pulled everything back apart, mc and caliper reinspected, cleaned and installed on the 96 everything looked good and seemingly worked fine...took the bikes out this fternoon and same thing happened within 20 mins!! So ima frustrated!

Hmmmm...

Have you put the bike on a stand, spun the wheel, and watched the brake rotor?

Foxx is right.
I see many brake systems that have sticky pistons.
In your service manual it recommends that you disassemble, clean, and inspect at regular intervals.
Few ever do.
What happens is you will build up goo between the two piston seals in each piston.
Then the piston tries to slide past that goo and it gets stuck.
I blow the pistons out with air, clean everything exceptionally well and pay close attention to cleaning the seals.
Your wife's tooth brush is excellent for cleaning seals.
Use a lint free rag.
Assemble with a little brake fluid.
It's amazing the difference it makes.

During rebuilding I pulled everything apart inspected ,cleaned thoroughly just like in the pics and in stalled New seals....figured this would've solved the issue....but no. This is why I'm perplexed...and as I explained to Foxx I even used a different brake line.

When you rebuilt the caliper...did you completely tear it down, and remove the piston(s) and inspect them too?...almost
sounds like a piston might be sticking.

When you say you "rebuilt both", are you referring to rebuilding the master cylinder as well?
You could possibly have a bad brake hose/line too. For the most part, brake hoses are interchangeable, so if you have another bike, you could swap hoses and try that, before spending the money for a new one...providing the one you swap out has enough slack in it, or is at least as long as the one on the bike now.

Yes, I rebuilt both the caliper and the mc....and, used a different brake line also. That's why I'm pulling a blank on this.

not sure about the '86...but a lot of guys use the smaller slimmer tank of the '89 250 on the '88-'04 500.

Does anybody know if the tank from an 86 KX250 is a direct fit on the 86 KX500? The radiator covers are the same but the 250 tank seems to be shorter, I think this mod would make my 500 look slimmer/lighter.

I see zero drawbacks, at 49 years old there is no chance in hell I am burning up a full tank before stopping, even the 250's lol