Project KDX500 has begun !

[drewh14]

How do you go about getting the KX street legal in terms of the DMV?

I'm not sure about NH, but here in MA its a P.I.T.A.  The only two ways i've been able to figure out are make the bike street legal, ie lights horn blinkers etc, and then bring it to the state police for a "custom vehicle inspection". i believe that is the same sorta inspection a garage custom chopper with a self welded frame would go through. but I've heard its not easy to pass. And even harder for a OHV that was never meant for the road.

The alternative (that I know has worked for a buddy) is to find a street legal frame. I'm keeping and eye out for something like a 90's KLX300 or KLR250. Then "adjust" the frame number on the KX500s frame to match. Find an inspection station that'll look the other way, and presto!


Again, theres not much of an easy way to do it in MA

[Polar-Bus]

This step was fairly straight foreward, and the fact I am using a '99 KDX200  wiring harness made this mod "almost plug-n-play. The only real modification was soldering a female bullit connector on to the lighting coil to plug into the KDX wiring harness :



The KDX voltage regulator has a convienent OEM connector:




The KDX headlight switch mounts nicely on the RH side of the bars, and plugs into the harness behind the headlight housing:



The headlight/ headlight switch sub harness'  plugs into a red and black set of connectors under the fuel tank:




And lastly the rest of the CDI, frame grounds, and kill switch connections are all color matched, and you just plug them all together near the coil:

[Polar-Bus]

A sweet OEM looking 2001  KDX500 A1 !!!




So that's it for now, this was a LOT of forethought, and i'm mentally spent. I still have to add a brake light banjo bolt switch to complete the swap, but i'm not worried about this now, as winter is almost here, and I will be only riding out on the ice.

Hope this thread detailed all the steps needed to do this swap well, and it will save you a ton of time !

                                                Rich K.

[drewh14]

That is absolutely gorgeous. I think you read my mind for what I planned on doing this winter, and beat me to it! Well now I have an excellent guide!

Thanks in advance!

[barryadam]

If anybody wants to do this, I have a bunch of original KDX parts available.
No need to buy a whole bike for a few parts (unless you need a frame).
headlight sets, light switches, original rear fenders with lights, etc.
No wiring harness, no frame.

PM me.

Barry

[johnny105]

Awesome job...

[Polar-Bus]

If anybody wants to do this, I have a bunch of original KDX parts available.
No need to buy a whole bike for a few parts (unless you need a frame).
headlight sets, light switches, original rear fenders with lights, etc.
No wiring harness, no frame.

PM me.

Barry

Which moder KDX ?  (I am looking for a 90-92 KDX250 rear fender ) ?

[slow600]

awesome conversion so far! what kind of wattage is that lighting coil rated for? the lighting coil on my kx5 is rated for 200w and the lights still dim down at idle.

[Polar-Bus]

awesome conversion so far! what kind of wattage is that lighting coil rated for? the lighting coil on my kx5 is rated for 200w and the lights still dim down at idle.

Reguardless of peak wattage output with a lighting coil, your lights will always go dim at idle. Most all dirtbikes with lighting use an "AC"  voltage system. If you converted to a "DC" type system with a 12V battery, the light will stay much brighter at idle, as now the battery is also assisting in the power supply at low rpm's.

[barryadam]

Which moder KDX ?  (I am looking for a 90-92 KDX250 rear fender ) ?

I have a 1999 and a 2001.  Both are identical except graphics.
Will these work?
I'll send you a picture after this weekend.

Barry

[Polar-Bus]

Which moder KDX ?  (I am looking for a 90-92 KDX250 rear fender ) ?

I have a 1999 and a 2001.  Both are identical except graphics.
Will these work?
I'll send you a picture after this weekend.

Barry

Barry, I would like to see if I can get the KDX odometer setup to work on the KX500.. maybe you can help me with some pics. I am mainly wondering how the KDX front wheel hub drives the speedo unit ?

[slow600]

my kit is dc with a battery, the lights dont go out just dim. just curious how that stator will work, it looks like it wouldnt power much. im constantly looking for options just in case my now-obsolete e-line stator craps out.

i do like that headlight a lot, im still trying to find a good looking replacment for mine.

[drewh14]

Polar,

For a spedo, I use Trail Tech Vapor

http://trailtech.net/vapor.html

It uses a magnetic bolt that replaces a bolt that hold the brake rotor, and a sesor mounted to the caliper senses the magnet passes as the wheel rotates.


Whats nice about the Vapor is its also a Tach, (numeric RPM and a bar graph), Ambient and engine temp gauge, odometer, backlight, battery backed up, and about a million other things that are listed on that link.

[KXcam22]

Polar,
  Using a mechincal speedo is a hassle.  I would also suggest the trailtech vapur or a bicycle speedo like I use.  The install is simple. I recently took the mech speedo off my sons KTM and replaced it with a bicycle speedo. Cam.

[IridiumRed]

Cool project, good job so far!!

I started putting together some parts for the same kind of project.  I dont know if its something that I'll get done in 2 months... or 2 years.... but I saw the opportunity and went for it

I found a 1989 KDX200 frame on Ebay that came off a bike  that was already street licensed / ridden in Iowa... !!

I'm in Missouri, and I hear it can be a bit troublesome to get a 2 stroke street legal, but... if you take a bike thats already been street licensed / titled, its no big deal.  The DMV doesn't even notice at that point.

That, and I have a friend at a shop here that will inspect / sign off on anything I bring him, so inspection is no problem.

I've got a 1997 KX500, with a fair number of mods (pipe, ported cylinder, balanced crank, new piston, etc etc), I'm going to put that engine in that KDX frame, and as many of the other KX parts that will fit

Btw, that KDX frame was only $180 shipped .... how could I pass up on that deal !


Anyways.  Good luck on your project, I'll let you guys know when I start on mine too