1985 KX500 questions

[Abbott]

Hey everyone. I just picked up an '85 KX500 from a friend who just dumped a ton of money into this thing. He recoated the cylinder, replaced the pistons and rings, new crank main bearings and seals, transmission gears, transmission forks and so on. he got it all back together and the bike would fire up no problem but the bike will not shift. Thinking he got the transmission forks in the wrong grooves or something. I won't know until I get here and am not too concerned with that.

I am going to purchase a manual soon for this but in the meanwhile, I wanted to pick some brains. Do the case halves and engine covers have their own gaskets (and where can I find these?) or does everyone use gasket maker to seal up the lower end of the motor?

[sandblaster]

Never done a 85, only back to 86.
I did find a gasket kit..

http://www.ebay.com/itm/Winderosa-808473-Complete-Gasket-Set-Kawasaki-Dirtbike-For-Kx500-1985-/361412154250?hash=item5425d7d38a:g:2woAAOSwl9BWJSI0&vxp=mtr

[Abbott]

thanks for the reply. i'll probably end up ordering a kit. it looks like the guy who was in there before me used some kind of gasket maker. I wasn't sure if the gaskets provided required "shimming" for the motor when being re-assembled.

[sandblaster]

Ok, I went to partzilla to look at a exploded diagram of your cases.
There is no main case gasket which is consistent with the 86-04 engines.
You will need a case sealant like Yamabond or similar.

http://www.partzilla.com/parts/search/Kawasaki/Motorcycle/1985/KX500-B1+KX500/CRANKCASE/parts.html

Before you do any assembly, wait for your service manual...

For a nice starter I have condensed a build on this site down to it's most informative parts here:

http://www.oem-cycle.com/forum/viewtopic.php?f=41&t=824

Basically I removed a lot of the banter (Which is fun reading) And kept just the info..

Same thing here;

http://www.oem-cycle.com/forum/viewtopic.php?f=41&t=878

Post pics when you can

[Abbott]

Thanks Sandman. really valuable information there! i'll post pictures when I can. looks like I cannot upload them directly here? I'm guessing I have to use photo bucket or some sort of image uploading site.

[umberto]

Here's a handy guide on how to post pictures. 

http://www.kxriders.com/forums/index.php/topic,10040.0.html

[Abbott]

[Abbott]

[Abbott]

[sandblaster]

Lookin sweet... I'd ride it 

[Foxx4Beaver]

that pipe's lookin legit.

[Abbott]

Thanks for the comments guys. Looking forward to hearing it run with that exhaust combination. That pipe has very minor dings on the bottom of it and is in overall good shape. It'll clean up real nice with some Mothers and aluminum foil

Started diving into the motor a bit this weekend. Took off the right side engine cover and removed the clutch to get at the kick start assembly was that sheared. was able to get a replacement off ebay for a good price.

the engine cover took quite a hit. broke off the boss that the kick start shaft rides in. I brought it into work with me today to try and glue the pieces back together so I can get a couple measurements. Going to mill a diameter into the cover where it broke and machine a new slug with clearance hole to be welded in. hopefully i'll be able to make it stronger that stock. i'll post pics when I can later

[Foxx4Beaver]

sounds good....keep the progress pics comin!

[Speedway73]

I've got a hand coned pipe for an '85 if you're interested. Been hanging from the rafters for YEARS. Not sure on manufacturer but it's solid non-the-less. Clean it up and give it a fresh coat of chrome or Hi-Temp...

Can post pics if you're interested.

[Abbott]

PM sent.

complete gasket kit is on its way, along with a new kick start shaft seal since that break ruined the other one.

How important are these resonator boxes? found that the one on this bike is all cracked. previous owner stuffed the cracks with gasket maker. I plan on mixing some MEK with black ABS plastic for some plastic welding. I've done it in the past and had good results.