SJJ's 1998 KX500 rebuild

[snoopjonnyjon]

The bike was bone stock when I bought it. Very minty for a 1998. There were a few little issues with it, but nothing serious.


I made a 500 look like a 80 sitting on it:cry:


I quickly discovered that the motocross sized tank was inadequate for the riding I do so I bought a Clarke Desert tank. At the same time I also bought an FMF Gnarly pipe and Powercore silencer. These add some low and mid to the bike, without a noticeable drop in top end. And I wanted the chrome. I also bought all new plastics and graphics to set the original plastics aside.



After a few tree induced knuckle injuries, I bought a set of hand guards.


Which takes me into this winter. I'm doing a full teardown and rebuild of everything.

[snoopjonnyjon]

Kickstand set in place





UFO Ghibli headlight (KDX/KLX replica)

[snoopjonnyjon]

Pulling main bearings off crank. Princess Auto to the rescue. Although the crank jig is genuine Kawasaki tool.




Pressing the crank into the RH case. This is where the crank jig comes in. it prevents the crank halves from pressing together.


Transmission all assembled and ready for install of the LH case.



Back together

[snoopjonnyjon]

Next up was the Moose lighting coil. I later ran the wire through the factory loom (which took about an hour to finally make work! Also, the coil interfered with the flywheel, so I had to machine down the baseplate 2mm.



I neglected to snap pictures of clutch, kickstarter or water pump install. But, here is a bottom end just begging for a cylinder... which unfortunately has not yet come.


And then switched attention to the rear suspension.
Pulled off the swingarm and linkage. Cleaned everything with solvent, then water/greaser, and finally toothbrush. Then repacked all the bearings with white grease and started reinstalling.

Here is the lowpoint.


Swingarm and shock back on.





Rear brake back on.

[snoopjonnyjon]

Cleaned up airbox and subframe, and put on the kickstand.





Here's my 3 graphics kits I got off ebay. All discontinued. 1997, 1998 and 1999.


And, the skidplate.

[snoopjonnyjon]

And my new piston, replated cylinder.

[snoopjonnyjon]

Sand paddle mounted











New front to match.




Repacking the silencer




Forks off for rebuild. I did pull the triple trees and packed the bearings and reinstalled.

[snoopjonnyjon]

I'll do the step by step stuff later on, as there were quite a few steps missed here. I have all the pictures, just not the time right now to tell the story. But here are a few complete teaser pics.









I still have a few things left to install, when parts arrive. Fork seals, fork guards, Devol aluminum rad guards, works connection frame guards, reed spacer, v force3 reeds, airbox mudflap, and the wiring for the headlight. It is running and riding again though.


http://www.youtube.com/v/4qMecD4xvhY

[500freak]

awsome bike!!!! and where did you get that fx graphics kit??

[snoopjonnyjon]

I got the graphics sets as old discontinued stock off ebay.

[Friar-Tuck]

  Hey Snoop,
 Looks like great work, I imagine the weather should be breaking soon.  Cabin fever must be at about Defcon 4...
   Let the Good Times Roll Big Guy!!!
  Tuck\o/  

[snoopjonnyjon]

No cabin fever for this guy. I ride in any weather! Here's an onboard video from riding my 1969 BSA Victor 441 (right foot shift, no signal lights, doing hand signals) around town last week. Riding antique street bikes in Saskatchewan, Canada in February  ... I thought I was just doing it for bragging rights, but I actually had fun. I think I will go for a ride everyday I have a chance from here on.

http://www.youtube.com/v/MZHvdI2LmKQ&hl=en_US

If you check out some of my other videos on my youtube, you'll see a few snowmobiling videos as well.

And as you can see from the youtube video in the prior post, that sand paddle works pretty good on the KX in snow. The motor will be broken in by the time spring rolls around.

There's a lot of fun to be had in the winter time, especially since I built this workshop. The ability to build a big fire and start working on projects makes winter my favorite time of year.

[blueoval]

Snoop, that is a FANTASTIC looking bike.  Great job!

[flyingfitz]

Great Job!  Pics like this keep me motivated!

Fitz

[kwakman]

GOOD WORK FELLA, SHE LOOKS FINE.WHAT BRAND OF SKIDPLATE IS THAT AS IM TRYING TO FIND ONE THAT WILL FIT AN 86,AND THAT LOOKS LIKE IT MIGHT.