new parts for old 5hundy

[iamsofaking]

Is it possible to get a new clutch hub for my 86 kx500? I tried to order one from Bike Bandit, but they sent me a message that it is discontinued. I know that Kawasaki doesn't sell them anymore, but does anyone out there have a connection for NOS Kawi parts? I really want to get this bike back in the sand.
Thanks.

[don46]

Are you talking the inner hub or the Basket? I think for the basket you may be able to use one from a newer bike, the hub your kind of stuck, the splines are different on your shaft thatn the newer ones and it onlys uses 5 springs rather than the 6 on the newer. Whats wrong with yours? Ebay may be your only answer, I've seen the hubs on there before. This is going to be a ongoing issue with the 86, 87, and to a certain extent the 88, parts are going to become harder and harder to find, the 89 to 04 won't be a problem for awhile yet but I'm sure there will come a point in time some of those will be hard to get a well.

[iamsofaking]

Are you talking the inner hub or the Basket? I think for the basket you may be able to use one from a newer bike, the hub your kind of stuck, the splines are different on your shaft thatn the newer ones and it onlys uses 5 springs rather than the 6 on the newer. Whats wrong with yours? Ebay may be your only answer, I've seen the hubs on there before. This is going to be a ongoing issue with the 86, 87, and to a certain extent the 88, parts are going to become harder and harder to find, the 89 to 04 won't be a problem for awhile yet but I'm sure there will come a point in time some of those will be hard to get a well.

I need the inner hub.  I bought an 87 from ebay, but the splines were different.  I keep looking, but haven't seen an '86.  I can find new baskets around, but have had no luck with the hub.

[BDI]

What about changing the shaft to work with the hub you got? Sounds like it could be a good upgrade if it would work.

[don46]

What about changing the shaft to work with the hub you got? Sounds like it could be a good upgrade if it would work.

I was thinking the same thing, the 86 uses a needle bearing opposite the clutch, the newer use ball bearings, hmm maybe the 87 uses the needle to, I'll have to look at that, or you may be able to use the shaft from a newer unit and use the neddle bearing, gotta think the cases weren't changed drastically.

[iamsofaking]

What about changing the shaft to work with the hub you got? Sounds like it could be a good upgrade if it would work.

I was thinking the same thing, the 86 uses a needle bearing opposite the clutch, the newer use ball bearings, hmm maybe the 87 uses the needle to, I'll have to look at that, or you may be able to use the shaft from a newer unit and use the neddle bearing, gotta think the cases weren't changed drastically.

Interesting.  I have been searching for this hub for a year now.  I wonder how tough it would be to get that shaft out.....

[BDI]

You will have to split the cases.Not a big deal really unless you don't know how or have the tools to do it.

[don46]

Looking at the fiche, it looks like you could use the shaft from an 87, and of course you'd have to use all the clutch compnoents as well. I don't think you could use the newer shaft from say 89 and up, it doesn't have the snap ring groove and probably isn't long enough. Maybe the 87 clutch is the same as the newer clutches, didn't look at that, if thats the case, you could replace the shaft and get a cluth setup off ebay cheap. I had a 86 hub, but one of the spring towers was broke off, I might be able to weld it back on. Whats wrong with yours?

[BDI]

I have fixed spring towers before by drilling the tower hole all the way through the hub then counter sinking the back side of the hub for a flat head phillips screw then I just screwed the tower back on from the back side with red locktite. Not exactly the way I like doing things but it worked.

[don46]

Great thought, they really only hold the spring in place.

[iamsofaking]

Looking at the fiche, it looks like you could use the shaft from an 87, and of course you'd have to use all the clutch compnoents as well. I don't think you could use the newer shaft from say 89 and up, it doesn't have the snap ring groove and probably isn't long enough. Maybe the 87 clutch is the same as the newer clutches, didn't look at that, if thats the case, you could replace the shaft and get a cluth setup off ebay cheap. I had a 86 hub, but one of the spring towers was broke off, I might be able to weld it back on. Whats wrong with yours?

One of the spring towers broke off.  Maybe I'll try the flathead screw technique.  That would at least get me going until a hub comes up on ebay. 

[BDI]

Looking at the fiche, it looks like you could use the shaft from an 87, and of course you'd have to use all the clutch compnoents as well. I don't think you could use the newer shaft from say 89 and up, it doesn't have the snap ring groove and probably isn't long enough. Maybe the 87 clutch is the same as the newer clutches, didn't look at that, if thats the case, you could replace the shaft and get a cluth setup off ebay cheap. I had a 86 hub, but one of the spring towers was broke off, I might be able to weld it back on. Whats wrong with yours?

One of the spring towers broke off.  Maybe I'll try the flathead screw technique.  That would at least get me going until a hub comes up on ebay. 

  If you do this make sure you get the screw tight and use red locktite you want to use as long of a screw as possible with out interfering with the spring retaining screw. if the screw was to come out it would make a real mess. The bike I first did this to lasted for years with no problems.I have never done this on a kx500 you will have to make sure that there is enough unused tower to thread a screw in from behind once the spring screw is in. you might have to shorten the spring screw a little. If you do it you should post some pictures of the repair. You know you might be able to run a long screw all the way through the tower from behind and put a nut on the front side.You may need to grind the nut and screw down a little if need be to clear the clutch cover.

[MadKaw]

you might be able to take the old hub to a machine shop and get them to build one for ya. should be able to get the right demensions to have one cut.

[don46]

you might be able to take the old hub to a machine shop and get them to build one for ya. should be able to get the right demensions to have one cut.

The sleeper has awakened have you been hiding or what, haven't seen you around in awhile?

[iamsofaking]

you might be able to take the old hub to a machine shop and get them to build one for ya. should be able to get the right demensions to have one cut.

i am confident that a machine shop could make me one, but have never looked into doing so before.  I am worried that it would turn out to be a very expensive fix.  has anyone done this? 

In the meantime, I ordered one from cheapcycleparts.com and they haven't kicked back my order yet, so I am hoping that they have one somewhere.  If not, I will definitely look into the machine shop.  Drilling it out would be a last resort, but this thing is too badass to just sit for so long!