new project for winter 08/09

[KX500freak]

hey guys ,
figured i,ll post my new kx500 project i,ve bought just today 
3rd gear is on a holiday and will not come back 

but i managed to get hold of this beast for E 350 and do the repairs myself .
this way costs could stay low for me .

funniest thing ...these shrouds..you guys ever seen these kind of shrouds
i never did ..and i don,t like m  glad i have a spare set ..genuine ones ...

anyone 



^{edit:wrong valuta}

[The Flyin Hawaiian]

They were/are made by Acerbis. I remember seeing them back in the late 80s early 90s.

[nd4speed]

$350 bucks! Does it run?

[KX500freak]

They were/are made by Acerbis. I remember seeing them back in the late 80s early 90s.

aah !! ok !!  i really didn,t know that

thank you Flyin Hawaiian..

$350 bucks! Does it run?

i must have had a drink to much  ...it was 350 in euroos,still a bargain

it has been sitting in a garage for almost 2 years and nobody came for it ...
the kx500 is very much unwanted here in holland,it s all cr500 that counts .

and yes it does run 

[KX500freak]

got it @ home now .
seems in a decent shape ..few this and thats the usual for a neglected kx500

pic how it came home today

[hughes]

Very nice bike trailer. You should docoment your rebuild with photo's. I wish I did on my 500.

[KX500freak]

thanks hughes,
i,m proud on that trailer,its stainless steel and does have two aluminium boxes in the center,
but they,re not on it right now,had to transport a gsx750r with it.

and the wheels are my own touch,sure looks nice 

i will use this topic for a documented rebuild with all elements represented ,engine /frame /plasts /forks etc:

[KX500freak]

tomorrow i,ll start tearing her down to a bald frame 

[KX500freak]

so ,job done

bike is in bits,n pieces,its not very good maintained i discovered.

-no brake fluid in rearmastercontainer,total worn brake pads..to the metal,on a almost new disk
-one fork is leaking severe
-bearings in rearfork not greased properly,they can be saved though.
-chainguide on rearfork worn

got some pics of today,s work

[KX500freak]

and the piece that is in a very good condition for an 98
only 3rd gear need to be fixed ,the rest seems fine .
tonight i,ll start to tear the engine down .

[KX500freak]

well after taking off the cylinder  ,it looks brandnew
piston also  kips is ok also

but when i went to let the oil off,it was not good !
the lever for the clutch on the ignition side had a totally worn out seal,
due to this ,it has collected lot,s of dirt inside the cases and clutchcase


oh and clutchbasket and hub are new just as the plates soft/hard

did some research yet,issue is pointed out

[KX500freak]

the shape of the oil is analyzed by a great mechanic.

the water in it came through the cl.arm seal.
the stuff in it is from to little oil .

it has been sitting there at least 2 years so then its degenerated into separated layers of fluid,
glad i didn,t fire her up after purchase .

he said ,new oil for a one off flush then again new oil and then ready to race 

got pics cummin

[KX500freak]

i have a nice anecdote ,need to tell bout it 

got a message on our forum that some guy was visiting family 150 miles away,near the loc. the k5 was .
just to meet a guy who told him ..

he,d raced his nephews 125 now and then ,and figured he could go pick this k5 up to go ride it...
so my received message was about the guy so beeing happy i was buying it,
his relative prob.would live LONG and happy without getting killed by that particular k5 

[2 smoke juan]

Looking forward to seeing your progress - nothing better than a winter resto!

Can't believe you picked that bike up for 350 euros, total bargain.

I missed a '92 K5 earlier this year, completely original in mint condition, still on original chain and sprocket and rear tyre. It was owned by a 78 year old who still races a YZ490 in vintage events here in Scotland.

It went for ?1750, which i thought was a gift, maybe i need to plan a trip to Holland!

[KX500freak]

thanks ,your project is also very very inspiring

got this bike so cheap because its fairly broken and stood there for like 2 years 
3rd gear is gone and probably a lill more is damaged

also it came to me by a close friend of the shop it did belong to
so the price came down big time ,he needed the space 

lill update :

found out the clutchbasket is a pro-X
in the next weekend ill split the cases