86 KX500 need help

[Roostmad1]

hello everybody,can someone please till me will a 89 and later KX500 clutch cover fit my 86 500?,and what else is interchangable engine wise between my 86 and later 500s?,thanks

[18thparadox]

I have an 86 to and am learning its an odd ball. If you want an exact fit you can check the parts diagrams on the Kawasaki website. Under Owner Info on the kx homepage. Then I believe you select your bike, and click parts diagrams. Click on the part # you need (not the reference #) and another box will pop up. Click the yellow "?" and it will list any other bikes that used that exact part.

I'm sure other parts fit but I'm a noob at most of this. Some of the more experienced will be able to help you with that I'm sure. 

[byron909]

i have a 86 whole bike, and a 94 motor in a 08 kxf frame. both motors apart right now. i'll check today. i do know the gasket is exactly the same all years with powervalve.

i bought my 86 in like a million pieces, had some extra cases and clutch cover. the clutch cover has been broken a bunch, and welded. it can be made right, i didn't bother becasue i already had a good one. if you need one, you can have this, just pay the shipping.
what all are you needing for your bike?

[Roostmad1]

Hi Byron,i only got the KX yesterday and already ive have had the top end of,was checking everything out before i started it and when i took the pipe of and looked up the exhaust port and pulled the powervalve open i noticed that somebody had not put the powervalves in right and they where not opening up properly,so i reset the powervalves and decarbed everything fixed the leaking head gaset and now has a truck load of compresssion the rest of the top end looks mint not even any wear on the cylinder lining,has i nice tight crank and main bearing which is always a good sign,i will be starting it today.what i do need mate is a intake manifold as mine is all cracked up and a air cleaner boot from the back of the carb(cracked as well) and how bad is that clutch cover you have,thanks very much for your help and look forward from hearing from you,cheers Richard

[byron909]

it has been repaired on bottom left, outer around KAWASAKI, and up by the water pump. it looks nasty, but wouldn't take much to make right. i just didn't bother, i had a better one. this cover is identical to my '94 motors' cover, so i would say all years powervalve 86-04 have same clutch cover. i don't have a intake boot, or the airbox boot. an 85 intake boot may not work, but the airbox boot would from 85-86 kx250, kx500. if you bought a rad vlave, and cut the boot mount off, and twisted, and re welded, your cracked intake boot days would be over. i am almost finished with my 86 resto, can't wait to ride it.

[Roostmad1]

Hi Byron,you must of been reading my mind about the rad valve mod,i was thinking about doing that just earlier today so i think thats what i will do, i managed to track down a clutch cover on ebay so hopefully i win it,my 86 is starting to look real nice,im not going to start it until i have mounted the exhaust properly as some muppet had made it solid mounted!!i9ve put some pictures in of the 500 and my 88 KX250 that ive been restoring,ive just finished mounting the pipe properly will at least it rubber mountd now

[byron909]

nice bikes, i had an 88 125 and 250 when i was younger, always liked them both. your 500 looks to be in good shape. i have oe barely used rear fender that would look much better back there.?
every 80's era kx anything i have owned has had pipe moount issues. even my 125's had trouble. a few 500's i once had were nothing but rattling messes, so this bike wanted to make sure it didn't happen. i have always liked the honda rear pipe mounts, so i added a few to this kx, as well as made a new upper. maybe this will give you an idea or something



welded tab to right front engine mount, tab on pipe, then rubber mounted the two together.



this is the stock location. somone had already made a new tab on frame. i made this from a cr125 head stay, think 5/16 thick. picture is hard to tell but the two are offset



this is on the rear of the chamber. i used to crack silencers, all kinds of wierd stuff. now i think everything will stay nice and rattle free, but still have give ifi t needs. still rubber mounted everywhere. those factory kawasaki pipe mounts never were a good idea.
here is how my 86 looked when i got it



picture does not do justice, this bike was ruined, besides making new engine mounts, i must have welded 4 or 5 cracks in the frame.
here is a link to some other stuff i have done so far

http://rides.webshots.com/album/576733989dbmoOX?vhost=rides

[Roostmad1]

mate you have mounted that KX pipe to the max!!, i dont think somehow it will be coming lose!!you have done a very nice job,i think that will make the kx more vibration free with all those mounts,i will have to put one at the back of the chamber like your've done,i'll have to invest in a mig welder at some stage,i have been working my way through everything but im getting there,all i need to do now before i can take it for a spin down the road is fit the chain slider (the one at the front of the swingarm) of a 88 as i can't get a new one and fill with anti freeze and gas and hold the hell on lol,,and yes i am interested in that rear fender how much do you want?,anyway as soon as shes running i will put some fresh pictures on,catch you later and have a great weekend,cheers Richard

[Roostmad1]

Hi Byron,just got the 500 going and its a minta,man im so happy,definitely hasnt done much work sounds real crisp and the motor is so quite no rattles there,started fist kick,mate has it got some compression not use to starting a 500 the 250 feels like it hasnt got any compression compared to the mighty 500, will take it for a ride tomorrow after the chain buffer is on,

[byron909]

looks like the bike wasn't ridden much! i wish i had your tank, mine is not looking good at moment. cool to see the old bikes!!

[kwakman]

thats a nice 86 roost.i'm doing mine at the minute and have sussed which bits fit from later models in most cases so give me a shout if your struggling.Byron, you do nice work.The older ones sometimes need more love but they go like a greased weasel when done properly, enjoy