BUILDING A STREET LEGAL KX500 SUPERMOTO

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I was cleaning my air box out and noticed that I had dirt inside the rubber boot that goes to the carb
Needless to say I was freaking out....
I checked the filter and it didn't seem to be coming though any part of it including the center bolt.
So I pulled the box apart and discovered the problem.

KX500 AIR BOX PROBLEM 1.JPG (29.29 KiB) Viewed 8791 times

KX500 AIR BOX PROBLEM 2.JPG (52.68 KiB) Viewed 8791 times

I almost cried when I saw the dirt...
The solution was a cage asy from a 99 kdx200 and some Permatex Ultra Black RTV Silicone.
Same size and configuration as the kx500

KX500 AIR BOX PROBLEM 3.JPG (44.92 KiB) Viewed 8791 times

Clean it all good...

KX500 AIR BOX PROBLEM 4.JPG (38.33 KiB) Viewed 8791 times

Ready to go...

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In transition

7-18-14 SUPERMOTO KX500 2001.jpg (88.26 KiB) Viewed 8790 times

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A little more progress..

01 kx500 rebuild progress 7-21-14.JPG (180.22 KiB) Viewed 8780 times

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A wee bit more progress...
Cheap Chinese rads look great but the holes never seem to line up

01 kx500 rebuild progress 7-22-14.JPG (179.35 KiB) Viewed 8776 times

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Almost ready...

01 kx500 rebuild progress 7-23-14.JPG (168.04 KiB) Viewed 8774 times

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Here's a quick recap..

https://www.youtube.com/watch?v=nnWQSe1 ... e=youtu.be

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Took her out for a short ride this afternoon.
So far I couldn't be happier.
The power comes on quicker and the engine revs faster then I have ever felt.
I couldn't flog it because I'm still in the break in mode but I can already tell this is the best engine I have ever built for the KX500.
Having the crank balanced is a huge plus.
I wish a I had a vibrometer to tell you what was happening at what RPM but I don't.
Butt Dyno result says it vibrates half as much as the stock bike maybe less.
I use to start my bike, set it on the side stand and it would vibrate circles around my driveway.
Now it sits there and purrs... Oh yeah.
I hope to have it ready to blow the cobb webs out by Saturday afternoon.
More info will be coming as I start opening it up.

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I had to go to the bank.
I had to go to the DMV.
I had to go to the store.
I had to go to the post office...
It's amazing how many errands you have to do when your super moto is running and the weather is nice

kx500 2001 super motor engine break in 7-25-14.JPG (59.83 KiB) Viewed 9140 times

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I took it out and rode it for about 50 miles city and hwy miles.
Combined with my previous rides I felt as though it is well broke it.
So I was at a favorite close to home mountain rd riding spot and I needed to pass some cars.
Dropped into 4th and wound it out, quick shift into 5th and pinned it WOT for a few seconds....
I was not disappointed in the least.
Now it's time to start playing with my next engine build with advanced port timing

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My buddy Jason taking my bike for a spin around the block..

https://www.youtube.com/watch?v=tURAvIx ... e=youtu.be