All specs provided are to the best of our knowledge accurate and true.
Please buy a shop manual and verify before using any of these specs.
Since this is a work in progress, don't hesitate to ask for specs not listed.
KX500 Engine
Because the engine ID's are not listed after 1989 here is a list of numbers based on bikes we have parted out as well as other member's numbers.
These numbers are subject to change as newer information is obtained.
1983 is KX500AE000001 - KX500AE001500
1984 is KX500AE001501 - KX500AE002400
1985 is KX500BE000001 - KX500BE001800
1986 is KX500BE001801 - KX500BE004100
1987 is KX500BE004101 - KX500BE006600
1988 is KX500BE006601 - KX500BE008500
1989 is KX500BE008501 - KX500BE010700
1990 is KX500BE010701 - KX500BE013000
1991 is KX500BE013001 - KX500BE01416x
1992 is KX500BE0148xx
1993 is KX500BE0160xx - KX500BE0164xx
1994 is KX500BE017257
1995 is KX500BE017933 - KX500BE0180x1
1997 is KX500BE0189xx
1998 is KX500BE0195xx - kx500BE0197xx
1999 is KX500BE0202XX - kx500BE0209XX
2000 is KX500BE021XXX - KX500BE0219xx
2001 is KX500BE022XXX - KX500BE0223xx
2002 KX500 KX500BE0233XX
2003 KX500 KX500BE0238XX - KX500BA03018X
2004 KX500 KX500BE0240XX - KX500BE0242XX
- KX500 ENGINE ID'S.PNG (32.29 KiB) Viewed 38102 times
1990 KX500-E2 JKAKXVE10LA002001 or KXS00E-002001
1991 KX500-E3 JKAKXVE10MAD04001 or KX500E-004001
1992 KX500-E4 JKAKXVE10NA007001 or KXS00E-007001
1993 KX500-E5 JKAKXVE10PA008301 or KXS00E-008301
1994 KX500-E6 JKAKXVE10RPD10001 Of KXS00E-010001
1995 KX500-E7 JKAKXVE10SPD11001 or KX500E-011001
1996 KX500-E8 JKAKXVE10TPDl5001 or KX500E-015001
1997 KX5OO-E9 JKAKXVE10VPD17001 or KX500E-017001
1998 KX500-El0 JKAKXVEC0WPD20001 or KXS00E-020001
1999 KX500-E11 JKAKXVEC0YPD23001 or JKAKXS00EEPD23001
2000 KX500-E12 JKAKXVEC0XI'D28001 or JKAKX500EEPD28001
2001 KX500-E13 JKAKXVEC01PD30001 or JKAKX500EEPD30001
2002 KX500-E14 JKAKXVEC02PD32001 or JKAKXS00EEPD32001
2003 KX500-E15 JKAKXVEC03PD3S001 or JKAKX500EEPD35001
2004 KX500-E16 JKAKXVEC04PD37001 or JKAKX500EEPD37001
KX500 Crankshaft Specifications
KX500 Connecting rod big end radial clearance
All years New .034-.047mm or .0013-.0018" Service Limit .1mm or .004"
KX500 Connecting rod side clearance
All years New .4-.5mm or .016-.02" Service Limit .7mm or .028"
KX500 Crankshaft bearing journal
29.97mm to 30.0mm or 1.180"-1.1811"
KX500 Crankshaft Runout
1983-1984 New .03mm or .001" Service Limit .075mm or .003"
1985-2004 New .03mm or .001" Service Limit .1mm or .004"
KX500 Cylinder head warp limit
New 0.00 - Service Limit .03mm or .001"
KX500 Cylinder and Factory Piston Specs.
If you are using any other piston be sure to check with the manufacture of that piston for the specs.
Yes, forged pistons need more clearance then cast.
Be safe, go the piston manufacture for clearance specs!!!
KX500 Cylinder diameter
1983 - New 86.000-86.015mm or 3.3858-3.3864" - Service Limit 86.10mm or 3.390"
1984 - New 86.010-86.025mm or 3.3862-3.3868" - Service Limit 86.10mm or 3.390"
1985-2004 - New 86.020-86.035mm or 3.3866-3.3872" - Service Limit 86.10mm or 3.390"
KX500 Piston Diameter
1983-1986 New 85.950-85.965mm or 3.3839-3.3844" - Service Limit 85.815mm or 3.3785"
1987-1989 New 85.910-85.925mm or 3.3823-3.3829" - Service Limit 3.3779mm or 85.76"
1990-2004 New 85.905-85.920mm or 3.3821-3.3827"- Service Limit 85.76mm or 3.3764"
KX500 Piston to cylinder clearance (Stock cast piston)
1983 New .045-.055mm or .0018-.0022" total clearance
1984-1986 New .055-.075mm or .0022-.0030" total clearance
1987-1989 New .105-.125mm or .0041-.0049" total clearance
1990-2004 New .100-.130mm or .0039-.0051" total clearance
The following info is taken from a Wiseco Forged piston factory box for a stock KX500 bore of 86mm.
Every Wiseco Piston has the Bore clearance on the side of the box so use this info for reference only.
KX500 Piston to cylinder clearance (Wiseco Forged) .0040" or .102mm
KX500 Piston ring end gap
1983-1986 New .2 -.4mm or .008-.016" Service limit .7mm or .028"
1987-2004 New .2 -.35mm or .008-.014" Service limit .7mm or .028"
KX500 Piston ring/groove clearance
1983-1986 New .05-.09mm or .002-.0035" Service Limit .19mm or .0075"
1987 New .08-.12mm or .0031-.0047" Service Limit .18mm or .0071"
1988-2004 New .05-.09mm or .0020-.0035" Service Limit .19mm or .0075"
KX500 Piston ring groove width
1983-1986 New 1.24-1.26mm or .049-.05" Service Limit 1.34mm or .053"
1987 New 1.57-1.59mm or .062-.063" Service Limit 1.67mm or .066"
1988-2004 New 1.24-1.26mm or .049-.050" Service Limit 1.34mm or .053"
KX500 Piston Ring thickness
1983-1986 New 1.17-1.19 or .046-.047" Service Limit 1.1mm or .043"
1987 New 1.1mm or .043" 1.47-1.49mm or .058-.059" Service Limit 1.4mm or .055"
1988-2004 New 1.17-1.19mm or .046-.047" Service Limit 1.1mm or .043"
KX500 Wrist pin OD
All years New 18.995-19.000mm or .7478-.7480" Service limit 18.96mm or .746"
KX500 Wrist pin hole ID
1983-1989 New 19.000-19.006mm or .7480-.7483" Service limit 19.07mm or .751"
1999-2004 New 19.000-19.020mm or .7480-.7488" Service limit 19.07mm or .751"
KX500 Connecting rod small end ID
All years New 24.002-24.013mm or .9450-9454" Service limit 24.05mm or .947"
KX500 Connecting rod side clearance
All years New .40-.50mm or .016-.020" Service limit .7mm or .028"
Wossner piston info
- wossner piston specs.JPG (44.66 KiB) Viewed 36816 times
- WOSSNER RING END GAP.JPG (43.15 KiB) Viewed 32366 times
SHIFT FORK FINGER THICKNESS
NEW 4.4-4.5MM OR .173-.177" SERVICE LIMIT 4.3MM OR .169"
SHIFT FORK GUIDE PIN DIAMETER
83-87 NEW 5.98-6.0MM OR .235-.236" SERVICE LIMIT 5.95MM OR .234"
88 ON NEW 5.98-6.0MM OR .235-.236" SERVICE LIMIT 5.88MM OR .231"
SLIDING GEAR GROOVE WIDTH
NEW 4.55-4.65MM OR .179-.183" SERVICE LIMIT 4.75MM OR .187"
SHIFT DRUM GROOVE WIDTH
NEW 6.05-6.20MM OR .238-.244" SERVICE LIMIT 6.25MM OR .246"
Electrical
KX500 Kawasaki Stator Specifications:
83-85 KX500 - 21003-1109 - 336-504 OHMS BLACK/RED TO BLACK YELLOW - 14.2-21.4 OHMS RED TO BLACK/YELLOW - 10.4-15.6 OHMS WHITE/RED TO BLACK/YELLOW
(2 coil style) 86 KX500 - 21003-1141 - 432-648 OHMS BLACK/RED TO BLACK/YELLOW - 4.0-6.0 OHMS WHITE/GREEN TO WHITE/RED
(2 coil style) 87-89 KX500 - 21003-1169 - 432-648 OHMS: BLACK/WHITE TO BLACK/YELLOW - 4.0-6.0 OHMS: WHITE/RED TO BLACK/YELLOW
90-04 KX500 - 153-230 OHMS (Ricky Stator says you can run it up to 350 with no issues. I have also ran them out of spec with no issues as well) BLACK/WHITE TO BLACK/YELLOW - 7.9-11.9 OHMS: WHITE/RED TO BLACK/YELLOW
KX500 Spark Plug
1983-1984 KX500 REGULAR B9EG, V-TYPE (GOLD) B9EGV, IRIDIUM BR9EIX
1985-1997 KX500 REGULAR B8EG, V-TYPE (GOLD) B8EGV, IRIDIUM BR8EIX
1998-2004 KX500 REGULAR BR8EG, V-TYPE (GOLD) N/A, IRIDIUM BR8EIX WITH A SOLID TERMINAL NUT
The spark plug gap for the 1983-2004 KX500 is .024"
IGNITION COIL
Primary (Small wire)
83-86 KX500 .85-1.15 ohms
87 kx500 .8-1.2 ohms
88-89 kx500 .85-1.15 ohms
1990 and newer .26-.36 ohms
Secondary (Spark plug wire)
83-86 KX500 5.0-6.8K ohms
87 kx500 5.6-8.4K ohms
88-89 kx500 5.0-6.8K ohms
1990 and newer 2.6-3.6K ohms
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KX500 Suspension
Non service related specs:
1985 - 2004 Kawasaki KX 500
Connecting Rod:
Big End Bearing (mm): 26x33x22
Big End Bore (mm): 33.00
Big End Width (mm): 21.97
Center To Center (mm): 145.00
Pin Diameter (mm): 26.00
Pin Length (mm): 54.40
Small End Bearing (mm): 19x24x25
Small End Bore (mm): 24.00
Small End Width (mm): 21.97
Washer Thickness (mm): 1
Jetting
The following chart is from Team Green.
I have found that it is a bit conservative.
Your not going to burn your bike up using them as long as your bike is in good condition.
However, for 0-1500 ft, stock engine, after market pipe, 92 octane fuel running 40:1 Motul 800, use 55 pilot, 168 main, stock needle at the 3rd position, 1.5 turns on the air screw and your rockin.
I use this on my Super moto and my Dunes/desert bike..
- kx500 jetting.jpg (113.71 KiB) Viewed 35833 times
