1991 kx500 (99% complete)

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12/23/2017 6:49 PM

Hey guys, did a rewind (vintage) race last year at Unadilla on a clapped 97 cr250 I bought 2 days before the race. I had a blast but decided moving forward I’d get a bike to wrench on over the winter to be ready for next year. Picked up a 91 kx500 that ran but had an issue with 3rd gear. It also has an 07 kx450 front end on it. I plan to make it a full frame up build, but no A kit, no titanium etc with my budget lol. The plan is to get a rolling chassis and then tackle the motor. Here are a few pics of it prior and a few progress pics. I’m honestly not sure on the end result as to what I’m going for but here are a few options I’m looking at. Enjoy! I’ll post as I go. Photo

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12/23/2017 6:52 PM
Edited Date/Time: 12/23/2017 6:53 PM

Re did the wheels. Cerakoted hubs, new spokes, powdered rims, sprocket, hardware etc. I’ll put new tires on it before I completely finish it.Photo
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12/23/2017 7:01 PM

Got the frame back from powdercoat and started to assemble the roller. I like the look of the silver anodized fork uppers on the TAC forks so I went with that look. Got a harbor freight blasting cabinet and some glass beads and what a tool to have. I’m replacing all the hardware, but the hardware I’m not (axles, linkage bolts, motor mount bolts, swimgarm bolt, etc) all got glass beaded and look brand new. So far the rollers coming along a bit, rebuilding the shock tomorrow and will be finishing up the roller I hope. I saw from sandblasted on another thread he mentioned a stock yz titanium spring would fit the 500 so I’m looking at putting one on I have sitting on the shelf. Also, the front end conversion was done half assed and the upper bearing sticks out of the race 1/2” so I’ll be taking the stem to the lathe to get it to fit properly. Getting there, again ON A BUDGET but doing what I can. Photo

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12/23/2017 7:04 PM

Lastly, a few pics of a couple ideas I’m tossing around. I like the clean 89 look, but the splitfire also catches my eye. Having a hard time tracking down a black tank and black side panels however for the splitfire look. Photo

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12/23/2017 8:03 PM

Your'e making great progress, just my opinion, but the blue seat cover and graphics looks great on all KX's, specially with a green frame. whistling

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There's something happening here, what it is ain't exactly clear.

12/23/2017 9:47 PM

Splitfire ??

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12/23/2017 10:41 PM

Very cool. Evo mx makes a kit to make it look just like Emig's 1996 Des nations bike. The seat cover is included. I've found companies that can make aluminum tanks too that are the smaller Kx 250 design. Photo

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Instagram: vanillaice782
Amateur helmet painter

12/24/2017 6:26 AM

i have lots of kawi gears in bags , new, send me part numbers, i have new fenders,and i got a handfull of TI yz springs

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12/24/2017 1:06 PM

smashingpumpkins167 wrote:

Very cool. Evo mx makes a kit to make it look just like Emig's 1996 Des nations bike. The seat cover is included. I've found companies that can make aluminum tanks too that are the smaller Kx 250 design. Photo

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I saw those! I’m half tempted because of the American flag seatcover for my Marine roots!

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12/24/2017 1:08 PM

pete24 wrote:

i have lots of kawi gears in bags , new, send me part numbers, i have new fenders,and i got a handfull of TI yz springs

Thanks pete I’ll keep in touch when I split the cases next week and see what the damage is. I wanted to get the roller all squared away so once the motors done I can just throw it in.

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12/24/2017 1:16 PM
Edited Date/Time: 12/24/2017 1:17 PM

Didn’t get much accomplished today just threw the swingarm and rear wheel on. Waiting on a few bolts, and to find my other axle block that my 2 year old “misplaced.” Photo

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12/24/2017 1:20 PM

And if you notice the stand, yes I did win a bike in rockymountain fantasy sx 2 years ago. It was a 2016 mod kx250f, sold it to my best friend who still has it today how it came with 12 hours on it. It’s only fitting I build a kx5 to put on this stand.Photo

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12/24/2017 11:23 PM

Looking good so far... I went mid 90s flo with my graphics...
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But I could be really, really tempted to do this...
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12/25/2017 6:25 AM

Awesome man, nice work so far.

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12/26/2017 5:13 PM

Few pics of some work I got done. Kx450 pegs, yz450 titanium spring, a little cleaning and blasting. Slowly coming. Correct hardware for brake coming just used these for mockup. Photo

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12/26/2017 6:05 PM

Looks great!

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12/28/2017 9:52 PM

A little more progress. I forgot to mention a ton of the stuff was plasti dipped so I have hours into peeling the stuff off, that was getting pretty old! I’ll be doing the stem next week and start taking motor apart this weekend. Again, nothing over the top fancy, on a budget, which is actually something I don’t really see people saying about their builds but I wanted to share. I got the bike as pictured above for $1100 and the goal was to be all said and done at $2500. Realistically under $3,000 for a frame up build I’d be happy with considering what I see them going for on the web. Lastly, I think I found my graphics scheme. I like the 89 look and these do a little bit two things for me. 89 is the year I was born, and I’m a big advocate of patriotism as a marine vet, so the 89 graphics with the American flag seem fitting! Lighting was bad in the living room but you get the idea. Photo

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12/29/2017 7:32 AM

Wow... very clean. It makes me want to get my 01 KX500 going again.
I see some Pro Action stickers on the KX450F forks.
I use to always use Race Tech.
Then I was involved in a build of a late model KX500 last year and we were being sponsored by several different companies.
Pro Action stepped up and gave us the parts we needed for our KX450F forks and KX500 Shock.
I was a little skeptical.
When we received the parts I compared against the Race Tech valves.
Amazing at how little difference there was.
One of the many things I liked about the Pro Action Valves is they came set up with the shim stacks all ready in order and ready to go.
The Race Tech valves you have to measure all the shims ID, OD, and thickness and stack them yourself which adds a considerable amount of time to the rebuild.
What about the performance?

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Our rider loves them cool

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12/30/2017 5:08 PM

Made a 15 hour round trip to pick up an 89 kx250 for the tank for the kx5. Finding one for sale that doesn’t cost a second mortgage is extremely rare. Then, I could only find a few 89 kx250s on the east coast. Of course the tank was spray painted black but it came off pretty easy. Have to sand her and polish it up a bit but it was a necessity for me atleast. Not the seatcover I’ll be using but just threw it on there for a general idea. Splitting the motor this week to assess the tranny problem. I did pull the jug off and looks like I’ll be sending it out sad Anyway, everyone enjoy their new year and I’ll update as I go! Photo

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12/31/2017 2:00 AM

You did good on the tank for sure!

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12/31/2017 2:27 AM

250 tank looks nice... I’m not desperate for one but I wouldn’t complain if I found one...
Bike is looking very clean!!!

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12/31/2017 2:33 PM

That's starting to look like a very nice motorcycle mate.

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12/31/2017 2:42 PM

Thanks guys! It’s getting there, doing what I can with what I got and the limited money I have lol I have a 2017 ktm 250sx that I’ll be posting in the builds next week once it’s finished thats a very nice bike, and I find myself caring more about this build than my brand new bike! Lol I did a few things today, cleaned the carb up and sanded and polished the tank. I don’t think it will ever be that brand new green so I’m calling this “good enough for most.” LolPhoto

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12/31/2017 11:38 PM

I think the tank looks great considering it's age and usage.
Somethings a little different about that carb..

The 91 KX500 came with a KEIHIN PWK V563
I don't see that ID on the side of the carb.
I'm wondering if it is a knock off..
Can you see any numbers on the side?
If not take a pic of the large end of the carb and post it.

For those that don't know a 38MM Quad vent air striker as came on the 00 CR250, 96-97 KX250 will flow more volume and higher velocity then a 41MM.
It will produce 1 more rear wheel HP and give you quicker throttle response then the stock carb...
Combine that with a VF2 reed set up and a 10mm reed spacer and you have a real winner..

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1/1/2018 5:38 AM

Sandblaster wrote:

I think the tank looks great considering it's age and usage.
Somethings a little different about that carb..

The 91 KX500 came with a KEIHIN PWK V563
I don't see that ID on the side of the carb.
I'm wondering if it is a knock off..
Can you see any numbers on the side?
If not take a pic of the large end of the carb and post it.

For those that don't know a 38MM Quad vent air striker as came on the 00 CR250, 96-97 KX250 will flow more volume and higher velocity then a 41MM.
It will produce 1 more rear wheel HP and give you quicker throttle response then the stock carb...
Combine that with a VF2 reed set up and a 10mm reed spacer and you have a real winner..

Hey sandblaster thanks for the kind words on the tank, I’m happy with it considering it’s age as well. As for the carb I remembered seeing the stamp on it when I was cleaning it. I do however have a problem with it between the cable and the cap. The old cable screwed into the cap while the new motion pro looks like its supposed to seat in there? Not sure what I’m going to do to fix it yet. Restoring these older bikes is actually super fun. I flip bikes on the side with my best friend to fund our own bikes (and this project) but it’s not the same. This is sentimental and doing the extra details, I certainly see why people do one after another! Anyways everyone enjoy their new year! Photo

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1/1/2018 8:01 AM

Sweet, that's the correct carb so if the cable don't fit right then I'd say you need a new cable :-)

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1/2/2018 3:36 AM

Looks great!

You may be able to buy the correct stem from Emig Racing. A 2003+ KX125, KX250, KX250F, KX450F stem is 6 mm taller than the 2002 and older KX125 / KX250, KX500, KDX, KLX stems.

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1/2/2018 3:58 AM
Edited Date/Time: 1/2/2018 3:59 AM

KDXGarage wrote:

Looks great!

You may be able to buy the correct stem from Emig Racing. A 2003+ KX125, KX250, KX250F, KX450F stem is 6 mm taller than the 2002 and older KX125 / KX250, KX500, KDX, KLX stems.

Emig racing does make a stem I could press in just trying to save a few bucks if I can strip it on a lathe. The problem is the stem is stepped in the middle and the kx5 upper bearing is 2mm inside diamager narrower than what the stem was designed for, so I’m going to try and lathe 2mm off of that step so the bearing will fit further down in. If it gets messed up, well then I’ll be shelling out some money to Emig racing lol

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1/2/2018 6:24 AM

KDXGarage wrote:

Looks great!

You may be able to buy the correct stem from Emig Racing. A 2003+ KX125, KX250, KX250F, KX450F stem is 6 mm taller than the 2002 and older KX125 / KX250, KX500, KDX, KLX stems.

bm201 wrote:

Emig racing does make a stem I could press in just trying to save a few bucks if I can strip it on a lathe. The problem is the stem is stepped in the middle and the kx5 upper bearing is 2mm inside diamager narrower than what the stem was designed for, so I’m going to try and lathe 2mm off of that step so the bearing will fit further down in. If it gets messed up, well then I’ll be shelling out some money to Emig racing lol

Or you can press the stock stem out and press it in the new trees. You can refer to my build thread "1992 KX500". I needed to make a adaptor washer/shim to make up the difference in the top tree vs stem.

The only challenge was the bottom fit was a few thou in the wrong direction so I knurled to increase the diameter of the stem and epoxy pressed it in the new tree.

If I had to do over. I would cut the top frame cup off and weld in a new cup to fit the modern bigger race. If you look at these 500 frames, the headtube is 3 pieces.

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1/6/2018 10:47 AM

pete24 wrote:

i have lots of kawi gears in bags , new, send me part numbers, i have new fenders,and i got a handfull of TI yz springs

Hey pete I split the tranny and found some wear on the cogs of a few gears. I was interested in seeing if you had any new gears left that are the same. You can email me at mxduke201@hotmail.com or text 5853141914 Thanks! The part numbers are 13260-1021, 13260-1102, 13620-1103.

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