Restoration Supermoto

2005 Kawasaki KLX 300 supermoto

The KLX may not be the biggest, baddest, best sumo out there, but its sure a hell of a lot of fun.

There is room for improvement in some things, which were addressed with rebuild. First and foremost is the suspension (front sprung for 155lb rider, rear sprung for 180lb rider, im 195 w/o gear). New suspension will be sent off and resprung and set up for my weight and motarding along with the shock refresh.

Also owner disliked the sluggish way the vacuum operated stock carb supplies power so it was changed out for a Mikuni 36MM pumper carb. the Carb also complimented the 351cc big bore kit from Bill Blue.

Project page –

Part list:

  • Powder coat frame, swing arm, engine mounts and skid plate Satin Black.
  • New bearings in steering head, swing arm, and suspension knuckle
  • 1994 KX 125 forks
  • Rebuilt suspension with proper springs for my weight
  • Anodized Fork tubes black
  • Custom machined spacers for ride height and axle
  • Powder coated shock spring Green
  • B&B 351cc Cylinder kit
  • Mikuni TM-36-68 Carburetor
  • MotionPro Vortex throttle
  • MotionPro Throttle Cable (Custom specs, 4″ longer, connector to mate with Vortex throttle)
  • Custom SS brake line (Russell components)
  • EBC Dirt Racers clutch kit with springs.
  • Green radiator hoses.
  • Renthal sprockets (15t/48t)
  • DID o-ring chain
  • Renthal Fatbar (CR High)
  • Renthal Grips (Med)
  • 2009 KLX250sf headlight (Custom fitted)
  • 2009 KLX250s headlight shrouds (Green and white)
  • CRG barend mirror
  • TrailTech Vapor
  • Moose Skidplate
  • Wide pegs
  • Moose shift lever
  • eBay Taillight from china.
  • 2010 Ninja 250R master cylinder
  • eBay levers for 250R from china
  • 2010 KLX250sf rear brake caliper (black)
  • EXCEL rims
MX Restoration

1992 Kawasaki KX 500 restoration and repair

Project –,46/1994-KX500,1327425

General specification:

  • Engine Displacement – 499
  • Engine Type – liquid-cooled, two-stroke
  • Cylinders – 1
  • Horse Power – 62
  • Transmission – 5-speed
  • Torque – 64.7 N-m 16.6 kg-m. 47.7 ft-Ib) @6000 RPM
  • Dry Weight kg – 100
  • Fuel Tank (gal) – 2.6
  • Fuel Tank (liter) – 9.9
  • Oil type – 10W/40
  • Front Tire – 80/100 R21
  • Rear Tire – 110/90 R19
  • Wheelbase – 1491mm (58.7in)
  • Wheel travel Front – 300mm
  • Wheele travel Rear – 330mm
  • Overall length – 2200mm
  • Overall width – 815mm
  • Overall height – 1205mm

This 1992 Kawasaki KX 500 was long coming project, because owner were looking for right motorcycle over year till this gem poped up. The goal was to update the brakes, wheels, suspension, clutch and all around fit and finish. And end result speak for it self.


  • 2011 Kawasaki triple trees got the stem pressed out and the KX500 stem pressed in
  • changed fork stops
  • the Brembo brakes and wheels are off a 2013 KTM
  • EXCEL Rim
  • new impeller drive gear old on the end of the crank shaft was beat to death, mushroomed and had broken teeth
  • made bracket to utilize KX 450 sliders
  • custom made wheel spacers
  • 450 cover
  • rebuilt shock, race tech gold valve and bladder cap
  • hydraulic clutch
  • cerakoted engine – tungsten color
  • ported cylinder and cleaned up power valves
  • new clutch basket
  • seat cover from MotoSeat
  • resotred PRO Circuit pipe

Simple way to upgrade the clutch pull arm for a little more leverage. Take a yamaha 450 pull arm shaft and this billet arm thats a tad longer, weld the splines to your 500 arm.

MX Restoration

1996 Kawasaki KX 250 rebuild

Project –,46/96-KX250-hybrid,1336043

Part list:

  • motor is getting a full rebuild with oem crank
  • powdercoated frame
  • powdercoated subframe
  • black wheels
  • cerakote hubs
  • purple shock
  • new zinc plated bolts
  • 96 oem graphics seat cover from Evo mx
  • Pro Circuite pipe
  • new r304 silencer
  • 06 kx450 forks (rebuilt)
  • 07 kx450 wheels, hub, rotor
  • axles, spacers & 07 kx450f brake system
  • EBC 280 kit brake kit
  • evo 96 decal kit
  • custom carbon fiber skid plate

Motorcycle specification:

1996 Kawasaki KX 250 specification