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KX500 Tard

422K views 2K replies 78 participants last post by  K5saveslives 
#1 ·
And so it begins..

 
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#59 ·
Trim a little at a time and you won't mess it up.



I used some self taping screws to help the fender to the sub frame:

 
#61 ·
If anyone else is interested in doing this I would highly recommend it.
Parts are readily available excluding one transmission bearing.
I may have to make a sleeve and use a different bearing, but, more on that later.
Nothing beats the sound of a two smoker on the street.
Those that know what you have give the thumbs up :thumbup:
Those that have no idea what it is are soon educated :bowdown:
 
#63 ·
Yeah it's a bummer but by no means are you stuck.
I'm working on a work around :)
There may be another manufacture that has it, I'm still looking...
 
#64 ·
Here is the part number and fitment.
Left engine case 92045-1233.
1989 KX250-G1 KX250
1989 KX500-E1 KX500
1990 KX250-H1 KX250
1990 KX500-E2 KX500
1991 KDX250-D1 KDX250
1991 KX250-H2 KX250
1991 KX500-E3 KX500
1992 KDX250-D2 KDX250
1992 KX250-J1 KX250
1992 KX500-E4 KX500
1993 KDX250-D3 KDX250
1993 KX250-J2 KX250
1993 KX500-E5 KX500
1994 KDX250-D4 KDX250
1994 KX250-K1 KX250
1994 KX500-E6 KX500
1995 KX250-K2 KX250
1995 KX500-E7 KX500
1996 KX250-K3 KX250
1996 KX500-E8 KX500
1997 KX250-K4 KX250
1997 KX500-E9 KX500
1998 KX250-K5 KX250
1998 KX500-E10 KX500
1999 KX250-L1 KX250
1999 KX500-E11 KX500
2000 KX250-L2 KX250
2000 KX500-E12 KX500
2001 KX250-L3 KX250
2001 KX500-E13 KX500
2002 KX250-L4 KX250
2002 KX500-E14 KX500
2003 KX250-M1 KX250
2003 KX500-E15 KX500
2004 KX500-E16 KX500
 
#66 ·
Yep your right.
Sorry for the heart attack fellas :lol:
92045-0013 is the superseded part number.
Fits the following:
2004 KX250-M2 KX250 CRANKCASE
2005 KX250-N2 KX250F CRANKCASE
2005 KX250-R1 KX250 CRANKCASE
2006 KX250R6F KX250 CRANKCASE
2006 KX250T6F KX250F CRANKCASE
2007 KX250R7F KX250 CRANKCASE
2007 KX250T7F KX250F CRANKCASE
2008 KX250T8F KX250F CRANKCASE
2009 KX250W9F KX250F CRANKCASE
2009 KX250W9FA KX250F Monster Energy CRANKCASE
2010 KX250XAFB KX250F CRANKCASE
2011 KX250YBF KX250F CRANKCASE
2012 KX250YCF KX250F CRANKCASE
Since I have all the other bearings ordered for the bottom end I'm going to get this one coming as well...
 
#67 ·
Done.
Takes about an hour if you have to remove the seat and side covers and then put them back on:



Unlike other fenders I have used, the 2005 KX250 rear fender has this area for the seat to ride up on.
So, what can you do to fix that?
You could put some stickers on it or in my case I will mount a tool bag back there



As you can see, the fender mod makes it look a bit more modern

 
#69 ·
Hmmmm :hmmm:
That's a good point.
Some guys cut theirs down but I have never seen a modded set that I like.
I am certainly open to suggestions.
For the time being it will be stickers, graphics or something similar..
 
#362 ·
On my 1996 XR600R Stupid moto mine looked totally dated too. Here's a pic on how I shaped them. Everyone who had an Xr here asked where I got them and wanted a set!

 
#70 ·
Testing the wiring BEFORE I put it all together which is a good idea with my electrical abilities :rolleyes:

Pencil point:
 
#72 ·
I investigated that procedure for Oregon and it was a no go...
Getting a lost title is easy and will cost you 77 dollars at the DMV.
Getting one for street use is a whole other problem.

This is from Oregon DMV:

Here is the info from the Oregon DMV:

Class III ATV
ORS 801.194 defines a Class III ATV as “a motorcycle that travels on two tires and that is actually being operated off highway.”

Note: Class III ATVs (“dirt bikes”) may or may not have been manufactured or equipped for highway use. To legally operate a dirt bike or similar vehicle on the public roads of Oregon, the vehicle must meet Federal highway safety and equipment requirements, Federal EPA requirements, and insurance requirements. See Imported Motorcycle and Moped Requirements, and Converting an Off-Road Motorcycle for Street Use.

Converting an Off-Road Motorcycle for Street Use
Can an off-road motorcycle be made street legal?
Before you convert an off-road motorcycle to ride on the street, there are some issues you should be aware of. The U.S. Environmental Protection Agency (EPA) has two sets of emission standards for vehicles, including motorcycles. The two standards are: 1) vehicles for street use and; 2) off-road vehicles (this includes dirt bikes, ATVs, UTVs, etc.). Your motorcycle must meet emission standards for street use (not off-road) before you can register it in Oregon.
How can I tell if my motorcycle meets emission standards?
There should be an emission label on your motorcycle. You will need to read the wording carefully. If it states “for off-road” or any other similar wording you will not be able to register your motorcycle. You can also check with a motorcycle dealer that sells your make and model of motorcycle. ODOT does not have this information.
What can I do to get my motorcycle emission certified?
First Step: Contact the manufacturer (not the local dealership) or the U.S. Distributor of the motorcycle, such as Honda or Yamaha, and find out if the engine has been certified through the US Environmental Protection Agency (EPA) to meet emission standards for street use. If the engine has not been certified for street use, you cannot make the motorcycle street legal. You cannot take your motorcycle to an Oregon DEQ testing station to get certified.
Second Step: If the engine does meet street standards, get a letter from the manufacturer stating that it does. The letter must be specific to your motorcycle and include the Vehicle Identification Number (VIN). It needs to include any modifications to bring the motorcycle up to street standards such as lighting equipment (includes all lights, turn signals, reflectors, high/low beam indicator), speedometer, rear view mirror, rims, tires, exhaust, carburetor, etc. Third Step: Keep all receipts for modifications. You will need the Manufacturers' Certificate of Origin (MCO), a receipt of ownership (bill of sale), and all your receipts for modifications, plus the letter mentioned above from the manufacturer. Fourth Step: Take the original letter and other documents to your local DMV field office to register the motorcycle. You may wish to call first to see if they want to visually inspect the vehicle for a vehicle identification number (VIN) at the time you register the vehicle.
.. For more information on U.S. EPA Emission standards: /ODOT/TS/docs/VehEq/Emissions.pdf
.. There are more answers to Frequently Asked Questions about vehicle safety requirements in Oregon at: http://www.oregon.gov/ODOT/TS/Veh_Equipment.shtml
.. For information on registering a vehicle, contact DMV at www.oregondmv.com
6/2008

DMV does not issue any permits or other type of registration for all-terrain vehicles, or other vehicles not manufactured for use on public roads except snowmobiles.

For permits and riding information, see Oregon Parks and Recreation Department.

Even though you do not get your ATV operating permits from DMV, you may still get a title for your ATV from DMV, although Oregon law does not require the title.

To get a title only for your ATV:

Fill out the Application for Title and Registration (Form 735-226) (this form may be used for title only);
Get a Vehicle Identification Number (VIN) inspection if your vehicle is required to have one:
You can get a VIN inspection at a regular or full service DMV office,
You will be charged a $7 fee for this service;
Submit the completed application to DMV; and
Pay the title fee.

License Plates
DMV does not issue any license plates for all-terrain vehicles, or other vehicles not manufactured for use on public roads.
 
#74 ·
The left red button Puts power to the rear brake light and all turn signals.
The right red button is for a small radiator fan.
The left toggle is for the flood beam.
The right toggle is for the pencil point beam.

 
#75 ·
I hate wiring.
I bought a harness off another bike with no directions....
Don't think I would do it again unless it was cheap :headshake

 
#76 ·
I'm ordering engine parts, bearings, gaskets, plating, ect in preparation for the engine build.
I have done a lot of reading on the subject of polishing the piston dome and the head.
Some say it makes no difference and is a waste of time.
Some say that is reflects the heat energy better.
Some say that it can rob power.
I'd like to hear your opinions and more importantly your experience.
 
#79 ·
my h2 piston have a little raised circle on the top of the dome, i smooth that down with 180 grit sand paper on a da sander, i balance everything to zero difference on multi cylinder bikes then run em...i also ALWAYS run full circle wrist pin clips too, i run them once one way then once the other way, then toss em in the trash....
 
#81 ·
Since you don't need a bunch of cold cranking amps, perhaps you could put together your own battery from some 18650 lithium ion cells? They're about 3.6 volt and decent ones are around 2 amp hours. When fully charged the voltage will be higher though, maybe 4.2 volts. They're pretty cheap and you can also rip them out of the inside of some types of laptop battery packs. EX: a 9 cell laptop battery would have 9 of em in it. Electricity isn't my strong suit, so just an idea lol.
 
#82 ·
Thanks for that.
Yeah, I looked at that as a possibility.
I finally settled on a Lithium Iron battery from Shorai.
I'm still working on the wiring and light choice so I'll post more info as time goes on.
Thanks again!
 
#83 · (Edited)
I've been playing around with some fans.
This one is from a KLR250



It's just too big.
I need something a bit more compact...
I have heard that KTM makes some that would be better.
Suggestions are always appreciated.. :)
 
#87 ·
Trail Tech Vapor Stealth Computer Kit :)

On the fan, the first thing I thought of was computer fan.
Then reality hit me and I thought, WATER!!!!
I'll check PayBay out for a KTM or Berg fan.
Thanks!
 
#88 ·
tons of attention to detail. reminds me of a member on customfighters with the detail work you are going through. i will say those 80s style number plates have to go:) you might as well throw the old rear fender and run a stock front on there if you keep those things:)

what about this:)



or this


ive never seen a retrofit side numberplate on a 500 before, mostly motor swaps into newer chassis, but im sure you can make it happen!
 
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