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Author Topic: 2001 KX500 Kawasaki Supermoto  (Read 325918 times)

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Offline sandblaster

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2001 KX500 Kawasaki Supermoto
« on: October 04, 2012, 10:29:46 AM »
BUILDING A STREET LEGAL KX500 SUPERMOTO.
Since I live in Oregon it is just about impossible to get a dirt bike made street legal.
Just a few years ago it was easy.
Put a dual sport kit on it, a high output stator, some Dot tires, a Quick DMV inspection and away you went.
I have heard of different ways of doing it, from paying off a DMV employee to re-stamping the VIN on a frame.
None of these ideas are good and can only result in serious trouble if you get caught.
The easiest way is to find a KX500 that was plated in Oregon before 2006.
I did manage to find a couple of frames that had been plated in Oregon but every deal I put together fell apart.
After a few years of frustration I found a street legal KX500 frame that had last been plated in Idaho.
I bought the frame and received the Title, current registration, and a plate.

So, I took the info to the DMV.
They wanted to do a VIN inspection.
No problem, I had the frame in the front seat of my truck.
The DMV person (Gender and name will not be used) inspected the VIN and we went back inside.
They disappeared into a back office for about 5 minutes.
When they came back I was told that they needed to see more of the bike then just the frame.
They said that it had to look like a motorcycle.
They said that the engine didn't have to be in it, but that it had to look like a motorcycle.
I'm thinking to myself, "How dumb is that?".
What difference would it make?
However, dumb that may seem that's my next step.
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #1 on: October 04, 2012, 10:30:21 AM »
Ok, the DMV want's it to look like a bike before they will transfer the title.
They said it didn't have to have an engine in it so this is what I have come up with:



I'll let you know what they say tomorrow  :D
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline kx5rider

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #2 on: October 04, 2012, 11:49:17 AM »
What are you using for a lighting coil?
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #3 on: October 04, 2012, 12:07:05 PM »
I have no idea......
Probably something like this:
http://www.kxriders.com/forums/index.php/topic,8353.0.html  :wink:
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #4 on: October 05, 2012, 09:01:21 AM »
I went to the DMV this morning.
There were further questions about the bike not having an engine or odometer.
I explained to them what I had been told the first trip in, that the engine was not required and nobody said anything about an odometer.
However, I told them that I would go back to the shop and get a odometer.
After looking the paperwork over they said it wasn't really necessary as there was no mileage on the bike from the previous owner.
So here was the result:



I have heard from a few people that after issuing a plate for a dirt bike the Oregon DMV requested the plates back after 4-6 months.
So, my next plan is to do only minor work to the bike until about 6 months has passed.
Once I'm in the clear, then I will get this project done.

Stay Tuned  :D
« Last Edit: October 23, 2012, 04:55:26 PM by sandblaster »
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #5 on: October 23, 2012, 01:50:49 PM »
A little more progress:
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Motorrad

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #6 on: October 23, 2012, 04:21:13 PM »
Quote from: sandblaster on October 05, 2012, 09:01:21 AM

I have heard from a few people that after issuing a plate for a dirt bike the Oregon DMV requested the plates back after 4-6 months.
So, my next plan is to do only minor work to the bike until about 6 months has passed.
Once I'm in the clear, then I will get this project done.

Stay Tuned  :D

we have the same issue here in california...

Mine had to look like a bike, and apss brake inspections, light inspections etc etc..

I actually hung a 4 stroke exhaust on mine before I went to take it through...    did the trick...    also took the kick starter off (makes it look less dirt bike like)....   as well as a few other tricks that are massivly illegal and I wont mention here..

You arnt safe untill the "renewal" goes through...

but within 2-4 months... the paperwork should have cleared (in our case sacramento)..    and your 90% clear..   only after that its a fluke

I danced and sang a song when my Kx made it past the first renewal.....


You should be safe though... they mostly watch for late modle stuff  (2004 and newer)
« Last Edit: October 23, 2012, 04:23:07 PM by Motorrad »
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #7 on: October 23, 2012, 04:32:40 PM »
Yeah I think I'm ok but we'll see.
If nothing else I'll have some nice clean and lubricated parts to sell :-)
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Offline Charlie500

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #8 on: October 23, 2012, 05:34:24 PM »
where are you at in oregon? I live in grants pass... I just moved up here from Bakersfield CA....
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #9 on: October 23, 2012, 05:50:51 PM »
About 2 hours north in Eugene.
Grants Pass from Bakersfield?
That's gotta be some culture shock  :-D
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #10 on: October 25, 2012, 11:37:48 AM »
I can't stand the stock K5 chain rollers:



Sealed bearings are much better :-)



I was all out of 97-04 KX500 forks so I did some research and found that the 96-98 KX125 and 96-98 KX250 forks have the same external dimensions.
So I just happen to have a pair of 98 KX250 forks in inventory.
As it turns out the only pair I have had the front brake hydraulic hose holder tab broken off.
So, I made a new one...



Perfect.
Upon disassembly I discovered that it had a brand new Hinson Clutch Basket with no wear. SCORE!



The cylinder plating is in excellent condition so all I need is a new piston and rings.
I could have re-used the old piston but why bother at this point?



Standard timing:



The rest of the disassembly went smoothly:







When I bought this bike I was told that 3rd gear was bad.
As it turns out, all the gears including 3rd looks good (Yes, even the dogs).
Here was the real problem:



That is the snap ring that holds 3rd gear in place.
No wonder it wouldn't stay in gear  :D
« Last Edit: October 25, 2012, 12:30:14 PM by sandblaster »
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Motorrad

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #11 on: October 25, 2012, 12:33:23 PM »
Ill take that hinson off your hands ...


thats the reason anytime I have a set of KX cases appart... they ALWAYS get new snap rings...   

(Usmc500 bitched about this... as added cost....   Told him I wont put it back together without)
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Motorrad

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #12 on: October 25, 2012, 12:34:06 PM »
Take more pictures of that CYL....   somone has had a dremel to it.
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Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #13 on: October 25, 2012, 12:52:44 PM »
Good eye.
I noticed it but didn't say anything about it.
I'll take some more pics tomorrow.
Thanks!
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Offline tobys 2 strokes

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #14 on: October 26, 2012, 03:32:26 AM »
Any body ever park a KLR 250 beside a kx 500 I have always played with the idea of transplanting a 500 into a klr 250 to make one street legal They go pretty cheep and should be comparable in wait.
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