BUILDING A STREET LEGAL KX500 SUPERMOTO

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More on that later..
So, I decided to put my two piece clutch cover on and start test riding it to make sure it will hold up for the long haul.
After thoroughly cleaning the inner clutch cover up, installing new bearings and seals, and installing the governor rod, governor, ect I tried to install it and discovered a problem.
The main KIPPS shaft was stuck.
I tried to move the shaft but it was really stuck.
I next pulled the pipe off and looking into the cylinder... Sure it was locked up but I couldn't see why?
So i pulled the cylinder off and now the lever works fine... WHAT????

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Nothing unusual here... Although it might be running a bit lean..

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Over all, I'm happy with how everything looks so where is the problem?

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5-19-14 kx500 top end rebuild 3.jpg (206.15 KiB) Viewed 9839 times

Again, nothing out of the ordinary..

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Again, a little lean but no biggie..

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Then, I found the problem...
When I put a little pressure on this valve guide, the KIPPS stop moving.

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I put a straight edge over the other valve guides and this is the only one sticking up about .002" above the surface of the cylinder base.
So, I grabbed a cylinder I've had sitting on the shelf for a while, put it on the engine and it works perfectly.
With my thoughts verified I decided to install the new cylinder, a new Wossner windowed piston, a new Larry modded head with compression release, and re-jet my carb.
Oh yeah, and install my 2 piece clutch cover...

5-19-14 kx500 top end rebuild 9-1.jpg (211.28 KiB) Viewed 9839 times

New studs, check.
Ring end gap .018", Check
Circlip opening up, check
Writing on rings up, check
2 stroke non synthetic break in oit, check
Head gasket with the small holes to the right, check

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KIPPS move smoothly once the inner clutch cover is installed, Check

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Water pump impeller clearance mod... Check

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New red hoses, check

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Everything bolted and torqued to factory specs, check.

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Plenty of clearance, check.
Motor turns over smoothly..
More later...

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I should be able to start heat cycles tomorrow..

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I was asked at another site if you were to raise the rear brake lever as high as it would go is there still clearance..
The answer is yes.
I was also asked if I have someone making some of these.
The adapter rings yes.
The welding, drilling and tapping, no.
What I did was adjust the rear brake set screw as far up as it would go, then I pushed up on the rear brake lever as far as it would go.

KX500 2 PIECE CLUTCH COVER BRAKE LEVER DEMO 1.JPG (91.13 KiB) Viewed 9871 times

KX500 2 PIECE CLUTCH COVER BRAKE LEVER DEMO 2.JPG (97.98 KiB) Viewed 9871 times

Poifect!

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Here is a pic of a KX450F Hammerhead shift lever installed on my KX500.
If you wear a bigger boot size you can order them in different lengths.
This one is 20mm longer then stock.

KX500 HAMMER HEAD SHIFTER.JPG (119.28 KiB) Viewed 9871 times