Posts
271
Joined
11/8/2017
Location
Fairport, NY
US
Edited Date/Time
5/14/2018 4:55pm
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. 
The Shop
But I could be really, really tempted to do this...
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?
Our rider loves them
Pit Row
Bike is looking very clean!!!
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..
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.
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.
However, you can send your entire trans out and have the dogs undercut, new bushings installed as required, micro shot peened, and all new snap rings installed from between 350-550 depending on how bad your is. I wanted to try out a vendor that offers this service so I sent him the very worst gears I had for a KX500 and they were really in sad shape. They came back ready to go and because the dogs are back or under cut, they should last longer then they did from Kawasaki.
Post a reply to: 1991 kx500 (99% complete)