BUILDING A STREET LEGAL KX500 SUPERMOTO

Bike Builds and rebuilds. Post pics and discuss your projects.
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Sandblaster
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Tue Jul 15, 2014 1:07 am

I was accused of having OCD.
So?
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If bikes are for kids I'll never grow up.

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Sandblaster
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Thu Jul 17, 2014 12:14 am

Still finishing the last of the cylinder clean up.
But for now I'm finishing the bottom end...
What we have is all the oil passages have been cleaned up, all mating surfaces have been lapped with Timesaver, bearings, seals, gaskets, shift forks, shift drum, and every snap ring, has been replaced.
The crank has been welded, trued, and balanced and rebuilt, using a IMS Pro rod.
Windowed Wossner piston, stock bore, fresh plate.
Transfers, bridges, and exhaust port, has been cleaned up.
Water ports have been cleaned up and the impeller clearance mod is done.
2 angle squish band with decompression on the head.
The rest is just glitter...
So, it should be just a nice, smooth, stock motor with some cleanup.
How will it run?
I should find out very soon.
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20140716_165249.jpg
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If bikes are for kids I'll never grow up.

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Sandblaster
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Fri Jul 18, 2014 1:31 am

The top end is back on.
So tomorrow I will take the chassis out back and wash it really good.
Also, I'm going to pull my air box off the bike and completely clean it inside and out.
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Fri Jul 18, 2014 9:40 pm

I was cleaning my air box out and noticed that I had dirt inside the rubber boot that goes to the carb :o :o :o :o :o
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
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KX500 AIR BOX PROBLEM 2.JPG
KX500 AIR BOX PROBLEM 2.JPG (52.68 KiB) Viewed 2504 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
KX500 AIR BOX PROBLEM 3.JPG (44.92 KiB) Viewed 2504 times
Clean it all good...
KX500 AIR BOX PROBLEM 4.JPG
KX500 AIR BOX PROBLEM 4.JPG (38.33 KiB) Viewed 2504 times
Ready to go...
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Fri Jul 18, 2014 10:21 pm

In transition
7-18-14 SUPERMOTO KX500 2001.jpg
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Mon Jul 21, 2014 9:39 pm

A little more progress..
01 kx500 rebuild progress 7-21-14.JPG
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Wed Jul 23, 2014 6:29 pm

A wee bit more progress...
Cheap Chinese rads look great but the holes never seem to line up :shock:
01 kx500 rebuild progress 7-22-14.JPG
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Wed Jul 23, 2014 10:08 pm

Almost ready...
01 kx500 rebuild progress 7-23-14.JPG
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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Thu Jul 24, 2014 3:17 am

If bikes are for kids I'll never grow up.

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Re: BUILDING A STREET LEGAL KX500 SUPERMOTO

Post by Sandblaster » Fri Jul 25, 2014 3:45 am

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.
If bikes are for kids I'll never grow up.

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