KX500 Parts not available and possible solutions

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Sandblaster
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KX500 Parts not available and possible solutions

Post by Sandblaster » Fri Apr 07, 2017 2:14 pm

A lot of people have noticed that several parts for their KX500 are no longer being manufactured.
It's sad but true.
This thread will attempt to give a list of what is NOT available and possible solutions for getting replacement parts or getting worn out parts repaired.

First off, consider eBay or Facebook as a source for used parts.
Always buy from established sellers with good ratings.
If someone wants you to send a PayPal payment, DO NOT send as (Family and Friends). If the seller is dishonest you will likely never re-coup your money. Send the money as (Goods or Services). If a seller is dishonest, you will get your money back if you file a claim within 30 days of the beginning of the transaction..
If bikes are for kids I'll never grow up.

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Re: KX500 Parts not available and possible solutions

Post by Sandblaster » Fri Apr 07, 2017 2:21 pm

14001-5258 89-04 KX500 Crankcases: Obsolete
You can repair a lot of damage.
Before looking for a used case which can cost 400+, consider getting yours repaired.
We have repaired some really bad cases and they work perfectly.

KX Guru Racing is working to have new billet cases made.
They will be expensive and there is no date for availability :?
KX GURU RACING KX500 BILLET ENGINE CASES 1.png
KX GURU RACING KX500 BILLET ENGINE CASES 1.png (85.92 KiB) Viewed 1981 times
KX GURU RACING KX500 BILLET ENGINE CASES 2.png
KX GURU RACING KX500 BILLET ENGINE CASES 2.png (143.2 KiB) Viewed 1981 times
KX GURU RACING KX500 BILLET ENGINE CASES 3.png
KX GURU RACING KX500 BILLET ENGINE CASES 3.png (135.2 KiB) Viewed 1981 times
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Re: KX500 Parts not available and possible solutions

Post by Sandblaster » Fri Apr 07, 2017 2:35 pm

59051-1150 86-04 KX500 GEAR-SPUR,IDLE,26T KICK IDLER GEAR: Obsolete
Generally, the teeth are ok, but the bronze bushing is worn out.
You can press out the old bushing and have a new bushing made.

KX Guru Racing is working on rebuilding these.

Image

We are also working on a upgrade..

Image
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Re: KX500 Parts not available and possible solutions

Post by Sandblaster » Fri Apr 07, 2017 2:47 pm

1st gear Output shaft - GEAR,OUTPUT LOW,32T 13129-1180 FITS 83-04 KX500: Obsolete

2ND GEAR OUTPUT SHAFT - GEAR,OUTPUT 2ND,26T 13260-1102 FITS 89-04 KX500: Obsolete

Many gears can be rebuilt.
KX Guru Racing is not offering this service yet but there are a few companies online that can undercut your gear dogs.
So, if the teeth are ok and the damage is primarily the dogs, they can be repaired.

http://www.aperaceparts.com/transmissions.html

http://www.mtperformance.net/trans_undercutting_service

We have not used either company so if you have any experience with them we would love to hear from you.

This vid shows what undercutting is:

https://www.youtube.com/watch?v=bl5SxlHo-rk

KX Guru Racing is working on getting them made new... No ETA on availability.
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Re: KX500 Parts not available and possible solutions

Post by Sandblaster » Fri Apr 07, 2017 2:52 pm

Shift Fork FORK-SHIFT,2ND&3RD 13140-1058 FITS 83-04 KX500

Shift Fork FORK-SHIFT,4TH&TOP 13140-1059 FITS 83-04 KX500

Believe it or not, even Kawasaki's new shift forks were not measuring up to their own specs :shock:
It's not just the fingers that get thin and below spec but the pin on the back of the fork that wears and causes major problems.

KX Guru Racing is working on making new billet forks with a replaceable pin.
We are also working on rebuilding worn out forks.

No ETA on any of this as of yet.
If bikes are for kids I'll never grow up.

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Re: KX500 Parts not available and possible solutions

Post by Sandblaster » Tue Oct 02, 2018 11:00 pm

Cylinders have now been discontinued... 11005-1564

Ouch...
If bikes are for kids I'll never grow up.

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