Maintenance & Technical > KX500 Super Motard
2001 KX500 Kawasaki Supermoto
sandblaster:
Ordered a bunch of parts today including all the snap rings for the transmission :-D
Tomorrow I am ordering all the bearings from Motorrads list:
Main bearings.
(NSK) 6306 ( Not sure what OEM rating is, but I run C3 rated) X2
KIPS bearings
(NSK) 608 (Stock is a C2 rating, I run C3) X2
Water Pump
(NSK) 608 (Stock is a C2 rating, I run C3) X2
Clutch Pressure plate
(NSK) 6001 (Stock is a C2, I run C3) X1
Shift Drum bearing
(NSK) 6905 (stock is a C2 I run a C3) X1
Transmission LEFT CASE
(NSK) 6305 (I run a C3, OEM is C2) (replaces OEM part number 92045-1011) X1
(OEM) This is the bearing My bearing house cant get.. so OEM it is 92045-0013 X1
Transmission RIGHT CASE
(NTN) 63/22 (I run a C3, OEM is C2) (Replaces OEM part number 92045-1134) X1
(special note on this bearing... ALOT of the ones out there now have a Plastic cage... Request a metal one, and CHECK IT before you leave
I Just dont trust plastic cages in transmissions....)
sandblaster:
I had a bit of a issue with the air box.
You can read how I resolved it here:
http://www.oem-cycle.com/forum/viewtopic.php?f=40&t=161#p306
sandblaster:
Remember the stock KX500 droopy rear fender?
It looked ok back in 1989 but we are a couple of decades down the road :D
One option is to get a newer rear fender and cut it up to fit.
So, which do you want to use?
I have used a 1992 KX250, 1998 KX250, and this is a 2005 KX250 rear fender.
These procedures work no matter which year of KX250 rear fender you use.
Since this will not bolt right up you will need a few tools.
I used a bench grinder, hand grinder, drill, and a marker.
The first thing I do is remove the seat, exhaust, rear fender, and side covers.
Then I take the 2005 KX250 rear fender and attach it to the sub frame with these two bolts.
And here:
I leave the bolts loose so I can quickly remove the fender for cutting.
As you can see, the rear fender is just pivoting on those two bolts.
Because of the exhaust clearance issues I like to start on the right side first.
I take a marker, put it through the exhaust hole in the sub frame and simply mark the outline of the exhaust hole:
A quick trip to the bench grinder, then remount with the two bolts and I use a hand grinder for touch up.
So far I like what I see.
Then I continue to mark area's that need to be removed, grind them, and touch them up until the fender fits as good as it can.
Last, I use some self taping screws to help the fender to the sub frame:
Unlike other fenders I have used, the 2005 KX250 rear fender has this area for the seat to ride up on.
So, what can you do to fix that?
You could put some stickers on it or in my case I will mount a tool bag back there :D
Done.
Total mod time?
About an hour.
Motorrad:
Looking sharp buddy... Im watching you :wink:
Need some ports like this for your build..
sandblaster:
Your right.... I could use some ports like that.
I'm watching you watch me :-P
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