Take a look: 2004 Kawasaki KX500
By Team TMX on 20th Dec 17
Sussex-based Boretech Engineering has developed a strong reputation for its classic and Evo MX machine rebuilds. Pictured is a 2004 Kawasaki KX500, the final production model of the big two-stroke.
Boretechs customer wanted the big Kwacker to be made into the ultimate, road-legal enduro machine. When it arrived, the KX was running badly and a full engine stripdown was called for.
The motor was totally stripped and all the castings shot-blasted and polished in-house. It was then rebuilt with a new con-rod, main bearings, a rebore and a Wiseco piston.
As most people ride the 500s in third gear, this was badly worn, so was replaced along with all the selector forks. The kickstart had a tendency to slip every other kick before the engine was stripped and so both of the kickstart gears were also replaced. New, heavy-duty clutch plates and springs were fitted to make the most of the fresh motor rebuild.
The chassis components were also stripped down and the front and rear suspension systems completely re-valved to suit the customers weight and riding style. The lower fork legs were black titanium nitride coated and the R fork legs hard anodised. Rear shock body was also hard anodised along with the Pro Circuit rear suspension linkage arms.
The front and rear brake calipers were treated to the hard anodised finish as well. A hand-crafted front exhaust pipe from Holland was fitted along with an American Pro Circuit tail pipe.
Oversize radiators help keep the 500cc two-stroke motor running cool over the longer events, and an oversize tank is fitted to keep the fuel stops further apart.
A full, battery-fed lighting kit was added and the whole thing topped off with Renthal Fat Bars, Talon wheels, Samco radiator hoses and Works Connection frame guards. Importantly for this type of road-legal conversion, Boretech also has a motorcycle MOT testing station and the KX was built to pass the MOT test so that it could be used on the road.
As you can see the finished job was a peach. Maybe not ideal for tight woods, but probably unbeatable on fast stretches.
Contact: Boretech Engineering on 01273 495405, info@boretech.co.uk or visit www.boretech.co.uk
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