KX 500 faults and fixes thread

[tomasaki]

My '01 KX5 hasn't idled worth a dang since the day I bought it off the showroom floor.  I doesn't matter how I jet the thing either.  It frustrates the hell out of me since I do alot of tight woods riding and idle alot.  I have to keep revving it to keep it running.  Replacing the stock reed valve with Boyeson Power reeds seemed to help.  I still had to cut some of the spring off of the idle screw so I coud turn it in further.   Any ideas???

[kawdude]

Mine has a similar problem but not as bad.  It will idle for approximately 15-30secs before it dies.
It's a pain in the rear.

[1alldave]

It appears that fuel tank cracking may be a common problem. My 99 cracked and leaked near the left side shroud mounts this summer. The 97  that I sold my buddy  just cracked and leaked in a similar location. Has anyone else had this problem? Any one have a stock tank they want to sell?

[mikesmith]

My tanks been in use since '95-no leaks or cracks.

[gwcrim]

If you're having jetting and/or idling problems, post what jets you are currently using and where you live.

I live in Ohio and have a 52 slow jet.  My bike idles but I think it's still a tad too rich.

Also take a look for vacuum leaks.

[John]

1. If the problem is that the engine comes to a sudden stop, an extra flywheel weight would help keeping the engine in motion.

2. If the engine slowly decrease the rews until it stops, check the carburetor jetting. (Usualy too rich, check the spark plug or the fumes when you start the engine).

3. If the idle "rolls" up and down, that would indicate a leak on the vacuum side.

This is my experience...

//John

[ramonaracer]

I have recently bought a KX 500 from Price Racing out of Las Vegas,  It was one of Shane Esposito's practice/race bikes.  The bike is awesome.

Some of the things they did to bullet proof it for desert racing were to:

Heliarc weld the entire frame.
Reweld the radiators.
Weld on protective loops for the waterpump and ignition.
Install a Hinson Clutch.
Take apart the airbox and seal it with good sealant
PC Valving for Desert 210lb rider Pro Level
PC KYB works fork kit
Installed a Pro Circuit Bladder in the shock
IMS footpegs and mounts
Renthal Bars and Sprokets
Mild Porting by PC
PC Pipe and jetting specs.
Extended clutch arm
Balanced crank from Falicon
Rear Disc Shark Fin
Excel Wheels, Talon Hubs, and Bulldog Spokes and Nipples
GPR Anti Vibe Bar Inserts/Stabilizer
BRP Chain Guide
IMS Tank with dry break valve


The only thing I didn't get was the trick PC forks that Team Green' Desert racers are using on their KX 500s.  Great pic in new Cycle News shows forks that  have much less underhang.  I am sure they are probably late model KX 250 forks with nitiride coating


Since I have had it I have drilled out the gas tank mounts and ran a 6mm or 1/4''  bolt through the tabs to tie everything together.  Now it is grade 12.1/8 with a double sheer.  

I replaced the crank bearings with close complement bearing that have two extra rollers as compared to stock.  Kaman Bearing in San Diego had them.  

Installed time serts in all of the head studs.  

I also drilled out the top shock mount on the frame and replaced it with a longer bolt that enabled me to get al nyock nut on it.  The bolt I used was off a 1987 Fourtrax 250.  It is the upper/lower A-frame bolt.  They come in different lengths so make sure that it is long enough that the spherical part of the shock won't be riding on the threads.  

Keep suspension and motor bolts tight.

This bike hauls and rides super smooth.  I am getting ready to start racing again after a long layoff, that whole school thing.

BE SURE TO USE LOTS OF LOCTITE, BOTH RED AND BLUE!!!!!!!!!!!

[teamgreen500]

Sounds Realllly familiar...


Manny

[demographic]

Installed time serts in all of the head studs.  quote]

Lost me there mate.

I don't want to sound stupid but what are time serts

Understood the rest but that one baffled me

[Rick]

Sounds like a great addition to the family.

One thought.  On the top shock bolt, instead of drilling out the threads, just purchase a stock top shock mount bolt from a newer KX125 or 250.  They use the same threads, but are longer, so you can add a nut to the bolt after you screw in place.

Just a thought...

Rick

[mikesmith]

Time sert are like a Helicoil.New threads,as in threads for a bolt.

[J.Patterson]

could it be Keensert?
http://www.keensert.com/

[demographic]

Time sert are like a Helicoil.New threads,as in threads for a bolt.

Ahhh, Helicoil.

Got it now

Ta muchly

[ramonaracer]

Thanks for keeping me honest.

Sorry for the confusion.  A time sert is an insert that replaces the threads by swagging the threaded insert into place where I think a keen sert has the hole  brouched then is inserted.  A time sert is kind of a cross between a heli coil and a keen sert.  Just my two cents

http://www.timesert.com/

Also thanks for the idea with the longer late model KX 125/250 bolt.  I drilled mine out because the threads got hammered from coming loose.

[gowen]

does anybody got any pictures of the top exhaust mount rig?