BUILDING A STREET LEGAL KX500 SUPERMOTO

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BUILDING A STREET LEGAL KX500 SUPERMOTO (K5SM).
Since I live in Oregon it is just about impossible to get a dirt bike made street legal.
Just a few years ago it was easy.
Put a dual sport kit on it, a high output stator, some Dot tires, a Quick DMV inspection and away you went.
I have heard of different ways of doing it, from paying off a DMV employee to re-stamping the VIN on a frame.
None of these ideas are good and can only result in serious trouble if you get caught.
The easiest way is to find a KX500 that was plated in Oregon before 2006.
I did manage to find a couple of frames that had been plated in Oregon but every deal I put together fell apart.
After a few years of frustration I found a street legal KX500 frame that had last been plated in Idaho.
I bought the frame and received the Title, current registration, and a plate.

So, I took the info to the DMV.
They wanted to do a VIN inspection.
No problem, I had the frame in the front seat of my truck.
The DMV person (Gender and name will not be used) inspected the VIN and we went back inside.
They disappeared into a back office for about 5 minutes.
When they came back I was told that they needed to see more of the bike then just the frame.
They said that it had to look like a motorcycle.
They said that the engine didn't have to be in it, but that it had to look like a motorcycle.
I'm thinking to myself, "How dumb is that?".
What difference would it make?
However, dumb that may seem that's my next step.

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Ok, the DMV want's it to look like a bike before they will transfer the title.
They said it didn't have to have an engine in it so this is what I have come up with:



I'll let you know what they say tomorrow

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I went to the DMV this morning.
There were further questions about the bike not having an engine or odometer.
I explained to them what I had been told the first trip in, that the engine was not required and nobody said anything about an odometer.
However, I told them that I would go back to the shop and get a odometer.
After looking the paperwork over they said it wasn't really necessary as there was no mileage on the bike from the previous owner.
So here was the result:



I have heard from a few people that after issuing a plate for a dirt bike the Oregon DMV requested the plates back after 4-6 months.
So, my next plan is to do only minor work to the bike until about 6 months has passed.
Once I'm in the clear, then I will get this project done.

Stay Tuned

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Here is some items that are often over looked.
Clean and not clean:





A little WD-40, 120 and 240 grit sand paper, and a quick trip to the wire wheel does wonders
I didn't want the polished look, just clean.
I also wanted to clean up the rough machine work on the edges.
I don't want to build a show bike, just a well oiled street sleeper

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One of the most abused parts and the least maintained is the shock arm link.
A good cleaning is in order.
Normally, when I get one this far apart I always replace all the bearings.
However, these bearings were like new.
So, I gave them a good cleaning, greased them up, and installed them.
Now, it's all ready to mount up:

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Today the 1994 KX500 Donor bike arrived.
Visually it looks good for a 94.
We know that 3rd gear is bad so we'll see what happens when we get it opened up

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As I was test fitting the parts I discovered that one of the sub frame inserts is stripped out.
It was fixed using a Heli-Coil.
However, the stock bolt could not be used and I wanted to use the stock bolt.
Here is a link to another article on how I handled the problem:

viewtopic.php?f=40&t=156

Here is some pics of where I am at.
Donor Bike:



K5SM



Every nut and bolt is being cleaned and lucubrated before assembly onto the K5SM.
I like it when the nuts and bolts fit properly

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After cleaning, inspecting, and greasing all the parts, assembly is required



It is nice working with clean parts...



Another area often over looked until it's too late is the chain adjustment bolts.
These weren't too bad yet:



After removing the bolts, I ran a die over them to be sure there was nothing to cause any problems.



Out with the old bearings and in with the new bearings:



Assemble as required...



Here is where we are at for today:



More to come so stay tuned...

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Finally fixed the threaded insert that holds the sub frame on.

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Ordered a bunch of parts today including all the snap rings for the transmission
Tomorrow I am ordering all the bearings from Motorrads list:
Main bearings.
(NSK) 6306 ( Not sure what OEM rating is, but I run C3 rated) X2
KIPS bearings
(NSK) 608 (Stock is a C2 rating, I run C3) X2
Water Pump
(NSK) 608 (Stock is a C2 rating, I run C3) X2
Clutch Pressure plate
(NSK) 6001 (Stock is a C2, I run C3) X1
Shift Drum bearing
(NSK) 6905 (stock is a C2 I run a C3) X1
Transmission LEFT CASE
(NSK) 6305 (I run a C3, OEM is C2) (replaces OEM part number 92045-1011) X1
(OEM) This is the bearing My bearing house cant get.. so OEM it is 92045-0013 X1
Transmission RIGHT CASE
(NTN) 63/22 (I run a C3, OEM is C2) (Replaces OEM part number 92045-1134) X1
(special note on this bearing... ALOT of the ones out there now have a Plastic cage... Request a metal one, and CHECK IT before you leave
I Just don't trust plastic cages in transmissions....)