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Author Topic: KX500 Supersport  (Read 114788 times)

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Offline Abbott

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KX500 Supersport
« on: September 07, 2016, 01:37:30 PM »
I started this build in another section of the forum but I thought it would better fit from here on out. if you want to see previous work done to the motor, click the link below.

http://www.kxriders.com/forums/index.php/topic,16138.0.html

The plan for this KX is to mount...

748 triple trees
748 Showa gold nitride forks
748 brembo calipers and masters
748 stainless lines
ducati 5 spoke marchesini wheel
CBR300R rear wheel and brake assembly
05-06 ZX6R rear sets and rear master cylinder
Clip ons

bodywork will be either ZX6R or Ninja 650R from catalyst Composites
Ninja 650R tank

There will be plenty of machining and welding going on over this winter, that's for sure! But the end product is going to be all worth it.
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Offline Abbott

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Re: KX500 Supersport
« Reply #1 on: September 07, 2016, 01:42:07 PM »
stock front end is off and old bearing races were removed. new bearings are on order and should be in soon. once they are in, I'll start measuring the spacers to adapt the triple trees.



Here are the showa Forks



front and rear wheels

« Last Edit: January 05, 2018, 10:27:55 PM by Abbott »
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Offline Foxx4Beaver

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Re: KX500 Supersport
« Reply #2 on: September 07, 2016, 01:46:18 PM »
nice!...
this'll be one of those cool/fun projects to keep an eye on, as you progress with it.
keep them pics com'in!
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Offline justreal

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Re: KX500 Supersport
« Reply #3 on: September 12, 2016, 05:20:40 PM »
Quote from: Foxx4Beaver on September 07, 2016, 01:46:18 PM
nice!...
this'll be one of those cool/fun projects to keep an eye on, as you progress with it.
keep them pics com'in!
   X2
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Offline Abbott

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Re: KX500 Supersport
« Reply #4 on: September 23, 2016, 02:25:20 PM »
Finally got around to making the triple tree adapter. pressed it with the bearing race into the head stock. the rest is all OEM Ducati that bolts right up together. minor details to finish up there. rear is next!!













« Last Edit: January 05, 2018, 10:28:21 PM by Abbott »
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Offline umberto

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Re: KX500 Supersport
« Reply #5 on: September 23, 2016, 04:07:25 PM »
Very nice work!  You shouldn't ever run out of front brake with that setup. I can't wait to see how the bike progresses.
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Offline Abbott

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Re: KX500 Supersport
« Reply #6 on: September 24, 2016, 08:09:02 AM »
hahah no kidding! it's practically 1-2 finger braking on my 748 and the KX will be almost half the weight. I can always remove a caliper and rotor if it's overkill
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Offline Abbott

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Re: KX500 Supersport
« Reply #7 on: October 10, 2016, 01:12:46 PM »
made a little progress this weekend. bled the front brakes...nice and solid now. mounted up the left clip on, bar, kill switch and clutch pertch. pulled apart the rear suspension components to clean and re-grease. it sounded like a creaky bed before!





hoping to start making progress on the rear wheel this week or next. I'll have pictures soon of that work.

« Last Edit: January 05, 2018, 10:28:33 PM by Abbott »
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Offline Abbott

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Re: KX500 Supersport
« Reply #8 on: October 15, 2016, 12:58:14 AM »
just finished machining the rear wheel to fit the 20mm ID bearing. I'll be assembling the wheel this afternoon so more pics to come soon...

« Last Edit: January 05, 2018, 10:28:40 PM by Abbott »
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Offline Abbott

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Re: KX500 Supersport
« Reply #9 on: October 15, 2016, 10:18:24 AM »
well, my swingarm pivot bolt is shot. the shaft is absolutely butchered because a previous owner completely neglected to reinstall the bushing that rides in the bearing.

anyone know if a newer pivot bolt will work? the one I have has a 24.5cm shaft length (minus the bolt head) and is 15mm dia. at the shaft and has a 14mm thread at the end
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Offline Abbott

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Re: KX500 Supersport
« Reply #10 on: October 17, 2016, 12:50:36 PM »
measured the wheel base on the KX tonight...came in at 1391mm with the axle closest in. my 748 is 1410mm...not bad considering the swing arm looked so long on this thing
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Offline Abbott

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Re: KX500 Supersport
« Reply #11 on: November 14, 2016, 04:39:21 AM »
well it's been a little while since I've posted but I've accomplished a good bit of work since. the rear wheel, final drive and rear brake assembly are all mounted and centered! was so glad to get this part done. all that is really left to do is make some sort of alignment boss to keep the rear caliper mount from spinning around. shouldn't be hard to do though.






I also picked up a set of those Chinese radiators for the '88+ KX500's. I'll give them a shot and see how they do. I read mixed reviews about the alignment and broken welds but I won't be jumping this thing or going off road so I hope the welds do alright. already have the left radiator completely mounted. have to make one more small aluminum bracket tonight for the right side and they will be all set.


« Last Edit: January 05, 2018, 10:29:24 PM by Abbott »
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Offline Abbott

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Re: KX500 Supersport
« Reply #12 on: November 14, 2016, 04:47:23 AM »
here is a side shot with the tank propped up on the frame. I have it "mounted" by the front of the tank where it slides onto a couple rubber bumpers. I have to wait for my tail piece to come in so I can see how much I will need to lower the rear sub frame and get my seat height correct. then I can weld in some flat stock across the sub frame and make a mount for the rear of the tank.

« Last Edit: January 05, 2018, 10:29:11 PM by Abbott »
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Offline sandblaster

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Re: KX500 Supersport
« Reply #13 on: November 14, 2016, 05:02:33 AM »
That is coming along nicely.. Great job..
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Offline Foxx4Beaver

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Re: KX500 Supersport
« Reply #14 on: November 14, 2016, 05:56:58 AM »
that's lookin sick!!
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Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ
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