Maintenance & Technical > KX500 Super Motard

kx500 supermoto (re)build

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KX500freak:
hey ,

this topic shows the rebuild of my supermoto.
i did build one but now i bought an former superbiker Kx500 engine.
so i go from there.
also i found out it,s been build by jan de groot,
he,s one famous kawi tuner in holland.

mods are a worked cylinder.
millet racing pipe
boyesen reeds

done list:

*7 unfinished factory welds finished (tip from bdi)
waterpump-protector
* millet pipe
(didn,t do the submount so it will snap instead of my handmade sub)

to do list :

*restore millet pipe

*regrease swingarmbearings
*paint
*new frontbrake setup

1stpic how it was
sec pic the piece i bought
3rd the millet pipe
4th engine dirty
5th engine clean  8-)

it came out like new  :lol:took me few hours of brushing

update,s r coming soon

paint next tuesday

KX500freak:
here,s a pic from the frame after welding
the angle is exact a little ove  the outersection of the waterpump.
this way it,ll take the hit instead .

KX500freak:
after like 4 hours of hard labour ,mostly done with a drill with steelbrush,
im proudly presenting the rehab. millet racing pipe :lol:
its shiny bare metal again,instead of the black rustpit it was..

also discovered 2 narrow cracks and i repaired a huge dent in the curlsection too
had to drill a hole on the opposite spot ,
and then used a thick steel rod to hit the dent back from the inside.
then welded it up .

its ready for rebuild  :mrgreen:

KX500freak:
today i went for the paintjob ,so my friends industrial oven for dogcookies was usefull.
its freezing -10 in holland at the moment..
so the pieces went into the oven after arrival for warm-up..
then the paint and then back in the oven for baking  :lol:
ready in less then 2,5 hours for the whole deal
results are great :-)
first pic is the baking proces
sec the endresult ,frame done  8-)

Dutch-K5 Fan:
So your bike has become a Champ k5 or a Pedigree k5 :wink: :wink:

Just kidding Menno.

 It looks great your man new frame, shiny Millet exhaust.



Dutch

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