Author Topic: 2001 KX500 Kawasaki Supermoto  (Read 325906 times)

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Offline Pmcg

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #15 on: October 26, 2012, 03:38:49 AM »
Looks like a great build.  I don't want to hijack the thread but am doing a rebuild myself and was wondering where is the best place to order the snap rings?  Any other must replace parts while you have the cases split?  Thnks

Offline Foxx4Beaver

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #16 on: October 26, 2012, 04:17:29 AM »
I can't stand the stock K5 chain rollers:



Sealed bearings are much better :-)





Absolutely agree....I slapped on a set of T.M.Designs rollers a few months back.Not only do they last way longer than stockers...but now the chain does'nt even come close to the sub-frame,(I do have a shield on the frame though,just in case  :wink:)

Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #17 on: October 26, 2012, 10:34:03 AM »
I finally finished fixing one of the threaded inserts that are used to hold the sub frame on.
A little welding, drilling, and tapping and were as good as new  :-)

The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #18 on: October 26, 2012, 10:35:29 AM »
Looks like a great build.  I don't want to hijack the thread but am doing a rebuild myself and was wondering where is the best place to order the snap rings?  Any other must replace parts while you have the cases split?  Thnks

I'm going to order mine from http://www.powersportsplus.com/
I have ordered a bunch of parts from them and they always seem to come through.
I plan on replacing all the snap rings.
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #19 on: October 26, 2012, 10:39:31 AM »
Here's some pics of the cylinder porting:

















The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #20 on: October 31, 2012, 02:45:20 PM »
Ordered a bunch of parts today including all the snap rings for the transmission  :-D
Tomorrow I am ordering all the bearings from Motorrads list:
Main bearings.
(NSK)  6306  ( Not sure what OEM rating is, but I run C3 rated)      X2
KIPS bearings
(NSK)  608    (Stock is a C2 rating, I run C3)   X2
Water Pump
(NSK) 608     (Stock is a C2 rating, I run C3)  X2
Clutch Pressure plate
(NSK)  6001   (Stock is a C2, I run C3)       X1
Shift Drum bearing
(NSK)  6905   (stock is a C2 I run a C3)     X1
Transmission LEFT CASE
(NSK)  6305   (I run a C3, OEM is C2)   (replaces OEM part number  92045-1011)         X1
(OEM) This is the bearing My bearing house cant get.. so OEM it is 92045-0013  X1
Transmission RIGHT CASE
(NTN)  63/22  (I run a C3, OEM is C2)   (Replaces OEM part number 92045-1134)  X1
 (special note on this bearing... ALOT of the ones out there now have a Plastic cage... Request a metal one, and CHECK IT before you leave
 I Just dont trust plastic cages in transmissions....)

The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #21 on: November 02, 2012, 12:46:22 PM »
I had a bit of a issue with the air box.



You can read how I resolved it here:

http://www.oem-cycle.com/forum/viewtopic.php?f=40&t=161#p306

The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #22 on: November 03, 2012, 07:12:14 AM »
Remember the stock KX500 droopy rear fender?
It looked ok back in 1989 but we are a couple of decades down the road  :D



One option is to get a newer rear fender and cut it up to fit.
So, which do you want to use?
I have used a 1992 KX250, 1998 KX250, and this is a 2005 KX250 rear fender.
These procedures work no matter which year of KX250 rear fender you use.



Since this will not bolt right up you will need a few tools.
I used a bench grinder, hand grinder, drill, and a marker.
The first thing I do is remove the seat, exhaust, rear fender, and side covers.
Then I take the 2005 KX250 rear fender and attach it to the sub frame with these two bolts.



And here:



I leave the bolts loose so I can quickly remove the fender for cutting.
As you can see, the rear fender is just pivoting on those two bolts.



Because of the exhaust clearance issues I like to start on the right side first.



I take a marker, put it through the exhaust hole in the sub frame and simply mark the outline of the exhaust hole:



A quick trip to the bench grinder, then remount with the two bolts and I use a hand grinder for touch up.



So far I like what I see.



Then I continue to mark area's that need to be removed, grind them, and touch them up until the fender fits as good as it can.
Last, I use some self taping screws to help the fender to the sub frame:





Unlike other fenders I have used, the 2005 KX250 rear fender has this area for the seat to ride up on.
So, what can you do to fix that?
You could put some stickers on it or in my case I will mount a tool bag back there  :D



Done.
Total mod time?
About an hour.

« Last Edit: February 13, 2013, 02:29:18 AM by sandblaster »
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Motorrad

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #23 on: November 03, 2012, 05:12:39 PM »
Looking sharp buddy... Im watching you  :wink:



Need some ports like this for your build..

« Last Edit: February 15, 2018, 07:27:29 AM by umberto »

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #24 on: November 03, 2012, 05:58:49 PM »
Your right.... I could use some ports like that.
I'm watching you watch me  :-P
« Last Edit: November 03, 2012, 06:01:44 PM by sandblaster »
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Motorrad

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #25 on: November 03, 2012, 06:46:19 PM »
Your right.... I could use some ports like that.
I'm watching you watch me  :-P

I'm watching you watching me watch you

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #26 on: November 05, 2012, 03:44:09 PM »
Today I installed the front fender and drilled the holes in it for the fairing pins.
I also discovered why you don't want to use a pre 96 K5 Swing arm with a newer K5....
The rear brake mount and caliper don't work!!!
So I had to find a newer swing arm, clean it up install new bearings and get it put back together..
Installed a rear brake with a SS hose and hydraulic switch for the rear brake.
For now I will stay with knobs and stock wheels.
I just want to get it on the road and see how I like it.
Once I decide if it will work for me then I'll get some better wheels and tires.
Here is where I finished up at for today:





Angry dog...

The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #27 on: November 05, 2012, 03:46:44 PM »
Tweakers keep trying to steal my broken trailer.
So I though I would leave them a message:

The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Motorrad

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #28 on: November 05, 2012, 04:21:07 PM »
Today I installed the front fender and drilled the holes in it for the fairing pins.
I also discovered why you don't want to use a pre 96 K5 Swing arm with a newer K5....
The rear brake mount and caliper don't work!!!
So I had to find a newer swing arm, clean it up install new bearings and get it put back together..
Installed a rear brake with a SS hose and hydraulic switch for the rear brake.
For now I will stay with knobs and stock wheels.
I just want to get it on the road and see how I like it.
Once I decide if it will work for me then I'll get some better wheels and tires.
Here is where I finished up at for today:





Angry dog...



what do you plan on running for a brake light / license plate mount?

Offline sandblaster

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Re: 2001 KX500 Kawasaki Supermoto
« Reply #29 on: November 05, 2012, 04:42:37 PM »
I have been looking online for something good.
Why, do you have something that I can't resist?  :-D
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.