KX500 Service Specifications page

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KX500 crank comparison 85-04
Here is the interchange info from Kawasaki.
85-86 KX500 - 86MM STD STROKE - 13031-1182
1987 - 86MM STD STROKE - 13031-1231
1988 – 86MM STD STROKE - 13031-1260
89-91 - 86MM STD STROKE – 13031-1285
92-04 - 86MM STD STROKE - 13031-1340

The crank bearings and seals are the same from 83-04.
The fly wheel taper and 12mm nuts are the same from 83-04.
The only differences I can find is the weight and the clutch side shaft.
The 85-87 used a key and a nut to hold the primary crank gear to the shaft.
88 and up used a snap ring to hold the primary crank gear to the shaft with no nut.
Kawasaki rods had different part numbers over the years but, the after market rods and rod kits are the same as well as the stroke at 86mm.
Here is a pic of the 85-86 kx500 clutch side of crank.

1986 KX500 CRANK SHAFT.JPG (122.51 KiB) Viewed 16381 times

Here is a pic of the 1987 KX500 crank.

1987 KX500 CRANK SHAFT.JPG (81.79 KiB) Viewed 16381 times

Here is a pic of the 1988 KX500 crank.

1988 KX500 CRANK SHAFT.JPG (75.94 KiB) Viewed 16381 times

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The pic below looks just like a 89-04 KX500 crank.
This pic is of a 1992-2004 KX500 crank.
Trying to determine the difference between the 89-91 and the 92-04.
I have heard that the 89-91 kx500 crank shaft is lighter then the 92-04.
But, that will require some verification.

92-04 KX500 CRANK SHAFT.JPG (58.79 KiB) Viewed 16383 times

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From what I can see, 85-87 kx500 crank shafts look identical.
From what I can see, 88 is the only kx500 crank shaft where it uses the snap ring on the primary crank gear but has the holes in the crank halves..
From what I can see, 89-04 crank shafts look identical.
So my best prognostication is that 85-04 can all be swapped as long as you have the correct primary crank gear asy to match the crank you are using.

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5-13-14 added jetting specs..

The following chart is from Team Green.
I have found that it is a bit conservative.
Your not going to burn your bike up using them as long as your bike is in good condition.
However, for 0-1500 ft, stock engine, after market pipe, 92 octane fuel running 40:1 Motul 800, use 55 pilot, 168 main, stock needle at the 3rd position, 1.5 turns on the air screw and your rockin.
I use this on my Super moto and my Dunes/desert bike..

kx500 jetting.jpg (113.71 KiB) Viewed 16362 times

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FMF JETTING RECOMMENDATIONS FOR SEA LEVEL AT 65-80F, 32:1 OIL/FUEL MIXTURE, UNLEADED PUMP FUEL, STOCK ENGINE
Then there is a whole bunch of disclaimers.
Basically, do pulg chops and watch your temps...

1988 KX500
MAIN JET: 175
PILOT JET: 62
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

1989 KX500
MAIN JET: 175
PILOT JET: 62
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

1990 KX500
MAIN JET: 170
PILOT JET: 62
NEEDLE: N82L
CLIP POSITION: 2ND
AIR SCREW: 1.5 OUT

1991 KX500:
MAIN JET: 168
PILOT JET: 58
NEEDLE: N82M
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

1992 KX500:
MAIN JET: 168
PILOT JET: 60
NEEDLE: N82M
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

1993 KX500:
MAIN JET: 168
PILOT JET: 58
NEEDLE: N82M
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

1994 KX500:
MAIN JET: 175
PILOT JET: 58
NEEDLE: STOCK
CLIP POSITION: 2ND
AIR SCREW: 1.5 OUT

1995 KX500:
MAIN JET: 168
PILOT JET: 62
NEEDLE: STOCK
CLIP POSITION: 2ND
AIR SCREW: 1.5 OUT

1996 KX500:
MAIN JET: 168
PILOT JET: 55
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

1997 KX500:
MAIN JET: 165
PILOT JET: 58
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

1998 KX500:
MAIN JET: 165
PILOT JET: 58
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

1999 KX500:
MAIN JET: 170
PILOT JET: 55
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

2000 KX500:
MAIN JET: 165-168
PILOT JET: 52
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

2001 KX500:
MAIN JET: 165-168
PILOT JET: 52
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

2002 KX500:
MAIN JET: 165-168
PILOT JET: 52
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

2003 KX500:
MAIN JET: 165-168
PILOT JET: 52
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

2004 KX500:
MAIN JET: 165-168
PILOT JET: 52
NEEDLE: STOCK
CLIP POSITION: 3RD
AIR SCREW: 1.5 OUT

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From Motorrads list of bearings...
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....)

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Compression Range in PSI
Kawasaki says the usable range is 105psi-164psi.
After a full rebuild ours are generally 190+
Anything below 140 and we rebuild the top end.