Well, been thinking of this mod for a while, and thanks to Ebay, and a few new 1999 KDX200 components, it's ready for the assembly transformation. My goal was to have a NH DOT legal KX500. I like the aftermarket kits, but they are $440+ . I purchased all the Ebay KDX lighting components and wiring harness for under $140. I had to purchase a new KDX headlamp/numberplate assembly, and this was the most expensive part at a whopping $75 ! I also purchased a new Moose KX500 lighting coil which was $69. So I came in at $284, and the best part is with KDX components, there is no need for splicing and hacking. The KX500's ignition wiring will perfectly merge with the KDX lighting harness and components. Lastly the OEM KDX headlight looks perfect on the KX500 ! I'll update this thread as progress advances.
So phase 1: Is retro'ing the KDX headlamp assembly to the KX500's triple tree. The upper brackets were a simple bolt on mod ! SWEET ! They are installed as pictured, and will work perfect for the upper mount of the headlight assembly:
Now things got more challenging. The lower bracket on the KDX's bolts to two casted standoffs on the lower triple tree. The KDX's standoffs are about 5-1/2" apart. The good news is there is two standoffs on the KX500's as well, BUT they are only 5" apart. I tried for hours to simply bend the lower bracket, but just could not make it work right. So a buddy of mine cut notches in the bracket tabs, bent them inward to 5", then tig weld filled the notches. I also had to machine flat the KX500 standoffs and tap two M6 holes to mount the lower bracket.
Here's a pic stock KX500, you can see the misalignment issue :
Here's a pic of the finished mounting. The lower triple tree is machined flat, tapped, and the bracket ears are cut, and re-welded :
So thats it for phase one. Here's a pic of the final mod. Looks OEM SWEET !! :
Next I move on to modifying the stator plate, stay tuned for phase 2.