HELP! I'm about to give up on my 86' KX500

[mowgoli84]

So as a few you of you may have saw in my introduction thread I picked up an extremely clean 86 KX500, by clean I mean showroom look.
Heres the problem. The motor is a hot mess.

I travel for work so I just decided to take it to a reputable (or so i thought) shop near my hometown. Took it in knowing it needed the following.
Rear Shock Rebuilt
Top end, Rings, Piston, etc.
Some other little stuff.

They had the bike for two weeks and I didnt hear anything, so Finally I call them and they say they have been looking for a piston and ring for two weeks and cant find anything...took me all of five minuets to solve that issue for them. I stop in the shop, my motor is in pieces in a rubber maid box, they tell me the crank is bad as well. So fast forward another two weeks, I call them today and still, they have nothing done! He tells me that they need various other parts, but they are discontinued... I had him email me the list.. I have searched the forum but cant find much. Where can I find these parts, and would 1988 to 1994 parts suffice?

Jeff, Here are the items that have been discontinued from Kawasaki and are no longer available.
 
Intake Boot                                  16065-1137
Countershaft Sprocket Lock Tab    92024-065
Float Valve Assy                          16030-1060

Any help would greatly be appreciated. I am about to give up and call it a day on this bike.. put it in storage with the rest of my vintage stuff. 

Thanks!
 

[sandblaster]

Here is what the book says:
Float valve: FITS 85-86 KX250 KX500 - 16030-1060
Intake boot: FITS 86 KX500  - 16065-1137
Lock tab 92024-065 Fits the following:
1974 KX250
1975 KT250-A
1975 KT250-A
1975 KX250-A
1976 KT250-A2
1976 KT250-A2
1976 KX250-A3
1977 KE250-B1
1978 KE250-B2
1978 KX250-A4
1979 KDX400-A1
1979 KE250-B3
1979 KX250-A5
1980 KDX400-A2
1980 KX420-A1
1981 KDX420-B1
1981 KX420-A2
1982 KDX450-A1
1983 KX500-A1 ('83 A1)
1983 KX500-A1 ('84 A2)
1984 KX500-A2 ('83 A1)
1984 KX500-A2 ('84 A2)
1985 KX500-B1
1986 KX500-B2
1987 KX500-C1
I don't have any of it....
Only one of these parts are on eBay:
http://motors.shop.ebay.com/i.html?_nkw=92024-065&_sacat=&_odkw=16065-1137&_osacat=0&bkBtn=&_trksid=p4506.m270.l1313

[mowgoli84]

Thanks for the response sandblaster.


I have found most of what I need. I found an intake boot off an 87 and i guess you can make it work.
Ordered two of the tabs...not sure why the said it needed it..considering the one that was on there was fine?

Found a site that claimed they had the float valve in stock so i ordered that. 

I'm sort of at a cross roads here. I don't want to run into this everytime I need to order something for this bike. I have always loved vintage stuff.. however, i think i shoulda found one a few years newer ;(

Money isnt really an issue but how much is too much.. I have newer bikes now and they require far less stress lol

Can I stick a newer carb on this bike? How much 88-94 carb and motor stuff is compatible wth an 86?

sorry for the newb questions but with all the other personal stuff going on right now I am about ready to let this bike sit...

any help is appreciated.

[turdle]

86 intake is straight,87 is angled to clear shock as 86/87 are two completely different frames.86/87 motors are pretty much the same. they only have the 2 kips valves,88 up has 3 valves.some stuff will still interchange just depends on what it is. if you like vintage/rare stuff, 86 is a good year. lots of firsts on it.1st year for kips on 500, rear disk brakes,2nd year for watercooled 500.last year they used a 40 MM carb.

[don46]

there are many differences, output shaft is different, clutch is different, crank is different, and by the way 88 only had 2 KIPS as well, 89 and up had 3. theoretically a new motor would bolt into your frame, you would have to modify the head stay mount as the 89 up head has a longer tab. When people ask, I always reccommend going for the newer motor as parts are more readily available. if your going for the vintage resto and don't plan to ride it thats a different story.

[mowgoli84]

Thanks for the input guys. I picked up a 2002 kx500 last week, and already have an 04, with work I can not spend time on the 86 anymore. I thought itd be a good project for me but I have no time ;/ I am out of town 5 days a week for work, and when I am home I just want to ride and relax.

So, the bike will be on ebay soon as a roller, I have the complete motor but its tore down in a couple boxes.

Let me know if you guys need parts, I would put money down that its one of the cleanest 86 kx500s on the planet.

ya'll can contact me at jsbishop84@gmail.com..

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