92 KX500 resto-mod

I've always had a thing for big bore 2 strokes. I have a fairly nice 87 CR500.



So I got this 92 KX500 on marketplace running for super cheap. I decided I'm going to make it "nice". Here is how it looked when I got it. When I'm done it won't be perfect but it will be decent. I am a very busy guy so I don't have a lot of time to spend so a lot of stuff is going to be sort of half-assed. I only have about 8 hours into the project at this point.





No cracks in the frame or cases (right side cover was broken)

Started tearing into it a bit:





Turns out we had an 87 engine and 92 frame. Both vins were clear though.

Step one was to take a look at the motor.



Some discoveries. Jug has been sleeved. Walls were scored. Not looking so great. Crank, rod, cylinder, piston, head are all 88+ (which is good because 87 and earlier pistons are not available).

Powervalve gear was shredded. Appears to be an 87 powervalve gear used with 88 crank gear. Obviously they didn't like eachother.



Ordered a used PV assy on ebay. Only other issue is kicker return spring hole on right case is cracked. That will be a simple weldfix.

Stripped down to bare cases and sent to a buddy for vapor blasting. Only have the cylinder done at this point (headed to machine shop tomorrow for 86.5mm piston bore)



Ordered new bearings and seals for the bottom end, as well as replacement water pump, right cover, kickstarter. The crank was out of true so I was able to hammer that back into spec (BARELY). Wound up at .0025" runout on the clutch side and .0039" (Spec is .0039")



Next it was on to the frame. Got it stripped down and sandblasted. Two spots needed light repair.



Dropped it off at a buddy's for powdercoat, as well as the shock spring.

While I was waiting for that to get done, I decided to clean up the tank. Only spent about 45 minutes on it so it's not perfect but a lot nicer than before. Used a DA sander up to 400 grit to smooth it out then used a pedestal buffer to shine it up. 1200rpm on 10" loose wheels with white rouge.

Before:





After:



Click this link for a little video of the shine:



Got the frame back from PC. Here it is all together. Similar to factory hue but a bit metallic.



Click the link for a visual of the "flop" in the PC.



I got some 92 forks from a buddy. Last but not least I buffed up some of the aluminum parts. Again, didn't spend a ton of time on them, maybe 2 hours total but got them looking halfway decent:















I ordered a bunch of shit for it. New wheels, ufo plastics, bars, chain, footpegs radiators, yada yada yada. Again, it won't be anything amazing when it's done but it'll be decent.

I'll try to keep y'all updated with progress.