kx500 supermoto (re)build

[KX500freak]

hey ,

this topic shows the rebuild of my supermoto.
i did build one but now i bought an former superbiker Kx500 engine.
so i go from there.
also i found out it,s been build by jan de groot,
he,s one famous kawi tuner in holland.

mods are a worked cylinder.
millet racing pipe
boyesen reeds

done list:

*7 unfinished factory welds finished (tip from bdi)
waterpump-protector
* millet pipe
(didn,t do the submount so it will snap instead of my handmade sub)

to do list :

*restore millet pipe

*regrease swingarmbearings
*paint
*new frontbrake setup

1stpic how it was
sec pic the piece i bought
3rd the millet pipe
4th engine dirty
5th engine clean 

it came out like new  :lol:took me few hours of brushing

update,s r coming soon

paint next tuesday

[KX500freak]

here,s a pic from the frame after welding
the angle is exact a little ove  the outersection of the waterpump.
this way it,ll take the hit instead .

[KX500freak]

after like 4 hours of hard labour ,mostly done with a drill with steelbrush,
im proudly presenting the rehab. millet racing pipe
its shiny bare metal again,instead of the black rustpit it was..

also discovered 2 narrow cracks and i repaired a huge dent in the curlsection too
had to drill a hole on the opposite spot ,
and then used a thick steel rod to hit the dent back from the inside.
then welded it up .

its ready for rebuild 

[KX500freak]

today i went for the paintjob ,so my friends industrial oven for dogcookies was usefull.
its freezing -10 in holland at the moment..
so the pieces went into the oven after arrival for warm-up..
then the paint and then back in the oven for baking 
ready in less then 2,5 hours for the whole deal
results are great
first pic is the baking proces
sec the endresult ,frame done 

[Dutch-K5 Fan]

So your bike has become a Champ k5 or a Pedigree k5

Just kidding Menno.

 It looks great your man new frame, shiny Millet exhaust.



Dutch

[KX500freak]

thanks peter!

    hell ,it even smelled like cookies when it came out the oven

but then again,who can say that he used a 70K Euro costing oven just for frame-baking 
the next day i,ll put it on its wheels ,engine goes in ,pipe goes on ,fenders and seat also.
so i,m busy on the last day of 2008

[GDubb]

Lookin' good! I cant wait to see this thing put back together.


-G

[KX500freak]

thanks Gdubb

i,ve been working my ass of today,
and i,m very very pleased with how the bike,s gonna turn out
i have 2 pics and it gives a good view on today,s progress.

_{since i,m gonna go out tonight i wanna wish you all a} happy new year !!!!

[Dutch-K5 Fan]

Looks like a brand new bike Menno.

Your realy on fire with your re-build. Mine is more a candel now.
Don't have the place to work on, only on work. But have more than enough time
no to complete al idea's and make a blueprint(in my head) how
I finaly will make mine bike.


Gelukkig Nieuwjaar alvast!!!
                Mogen 2009 een goed K5 jaar worden.
                     
                        Groetjes Dutchie 


PS   Happy Newyear to the rest!!

[KX500freak]

thanks man ,im so proud how it,s turning out .
beyond expectations 

en jij ook een heel goed en gaaf 2009 gewenst peter
dat we mekaar gauw eens kunnen treffen !

lookin forward meetin you in 09 

tomorrow more pics

[maddoggy]

dang Menno, that thing is looking great. you're really whipping that rebuild into shape. good job, looks sweet!!!               MADDOGGY

[Good]

Very nice.  The frame and pipe turned out great!!!  I wish I was getting as much work done as you are...

[KX500freak]

dang Menno, that thing is looking great. you're really whipping that rebuild into shape. good job, looks sweet!!!               MADDOGGY

thanks marty !!

i,m making shifts building this machine,but if i slow down ,i loose the pace
and i free for 3 more days ,then hard labour for a company calls  again:|

so here,s a fresh update !

tonight i,m going to mount the Millet,which is no easy task ,
since the previous owners had their ignitioncover half melted from the heat .
so im gonna rework the pipe-route ,so it stays clear of all obstacles.
 
Freak

[KX500freak]

Very nice.  The frame and pipe turned out great!!!  I wish I was getting as much work done as you are...

thank you too good !

maybe you can suck up some of my working pace ,then you go faster too 

lots of small things done like carb, cables ,rads ,fender  etc:

more pics later today 

[KX500freak]

as promised more pics of the science in progress,
calling it science because it,s not standard stuff ,nothing fits well after having been disassembled
just to mount the huge sucker of a pipe took me 2.5 hours and 2 re-located mounts..
but honestly who did ever see such a amazing huge pipe,
for sure i didn,t before this millet came around.