1991 Kawasaki KX500 Two Stroke Project Build - Motocross Action Magazine
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Published 2021-10-14
Motocross Action Magazine has tested a plethora of 500 two strokes over the years. Some good and some we are fine with forgetting. Many of the rougher rides are due to the builder using an older engine with a modern chassis. The modern chassis weren't built to have a 500cc two stroke engine slammed inside of it. This 1991 Kawasaki KX500 was a garage find and complete mess when it first got started. Tom Morgan did the engine and Jay Clark put the bike together. An FMF exhaust, Race Tech suspension, Hinson clutches, ODI handlebars, Dunlop tires, Supersprox sprockets, UNI air filter, and Motoseat seat cover were just some of the parts mounted to this old bike. The KX GURU racing crew used some of their own techniques to massage the suspension department and reinforce areas they know are weak on this model. Our managing editor Daryl Ecklund returned to the video side for the day and got to test the KX500 at Glen Helen Raceway. Check out what the Motocross Action Wrecking Crew thought about this unique build.
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All Comments (21)
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To me, this is the ultimate dirt bike. The pinnacle. Beautifully done!
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This is bringing back old memories. The year was 1991, I was an 11 year old and one day my dad came home with a brand new kx80 for me and a new kx500 for himself. I’ll never forget the sound of that 500 or trying to kick start that beast. Thank god for that decompression switch, otherwise trying to start that monster was damn near impossible
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Tom Morgan is my uncle🤘🏻 I got to see some badass prototype stuff when I was a kid. I remember he had a bunch of Blackfoot Honda’s in his shop he was doing up back in like 2000.
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Got 9th overall in the intermediate open class on my uncles '91 kx500 at a gutbuster 250 in yurington, nv. That was in 2001. I was 14. They were clocking people's speed on this long sandy straight section. On my 2nd loop, i clicked into 5th, and held it wide. They got me at 93 mph. Crazy thing is, the wind was damn near ripping my helmet off and choking the shit outta me so, i rested my left arm across the gas tank, got tucked so my chest was on top of my arm, and held the front of my helmet down. They took a picture of it too. It still hangs in RMS(reno motor sport) today. 93 mph on sand one handed holding my helmet on at 14 years old on a kx500.
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Best looking KX500 I've seen so far... They really brought it back with the original styled number plate and those shrouds had a huge hand in how it looks like a early 2000's bike, minus the Chevy bowtie logos.
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That brings back some memories. I went from racing a KX105 to the KX500 in 91'. My first big bike!
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What a terrific build! Wardy - if he watched this video - must have one big smile. Bummer you didn't dyno this baby, nor did you do a start vs. a 450 four stroke on Glenn Helen's long start - that would have been very interesting.
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Best looking kx500 i have ever seen
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Excellent job on the Video guys! Thanks for taking the time to share all the important specific details that all of us Moto Guys are thirsting for.
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The olde bikes were far better looking than what they are today!
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Awesome video, thanks guys!!
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Look's really stable,nice build 👍
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A beautiful bike!
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It's beautiful! The seat has that big dip that takes some getting used to. If you gear one 16-42 she will go 116 MPH.
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Really lovely looking kx500 mother cross bike like the green fantastic 👍😅
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Great looking bike kx 500 cc like the green guy's thanks for great content guy's 👍😅
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Super vidéo 💚💚💚
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Awesome build guys im in love🚀🔥😍😍
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Perfection!! Also great video
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We just finished 1 too! Let's do a 500 shootout at the national track mx338!
