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Storage 11 specialises in low-volume, high-quality restorations of classic motocross bikes from the Sixties to the 2000s. Based mostly in Victoria, these guys deal with almost each side of the method to keep up full high quality management over their builds. They’ve a repute for creating extraordinary machines, reminiscent of this gorgeous Kawasaki KX500, which seems as if it has simply rolled out of the showroom and into the studio.
Ah, the ’80s. A time of massive hair, loud garments, wild music, and, in fact, dust bike design. It was a wild interval for off-road producers and their pursuit of creating and inventing bikes that would go quicker and deal with higher than the earlier era. The period was characterised by immense trial and error, in addition to the unbelievable works bikes utilized by the highest manufacturing unit groups. In hindsight, these bikes could seem outdated in comparison with fashionable motocross bikes, however they’ll at all times retain their distinctive individuality, one thing that the trendy era of bikes usually lacks as a consequence of strict guidelines and necessities.
With that stated, let’s check out the 1986 KX500 that the group at Storage 11 managed to revive to its former glory.
ASSESSING THE DAMAGE
Storage 11 acquired this bike in early 2019, and it appeared as if it had been sitting on the backside of a dam for the previous couple of a long time. A lot of it was lacking, and the remaining components had been in critically unhealthy form.
Restoring bikes from the ’80s is at all times a problem. Details about them is changing into scarce, and since these bikes had been usually solely produced for a yr, many components haven’t been reproduced by aftermarket corporations, making them troublesome to seek out. We started by stripping down what we had so we may assess what we may salvage and what we wanted to seek out. The body, as an example, wanted to be sandblasted to evaluate its situation and what lay beneath the paint. Happily, the body was in actually fine condition, with only a few minor threads and bits needing restore. It was then coated in a manufacturing unit silver shade.
Whereas the body was being labored on, we observed that the entrance forks had been in unhealthy form, in order that they needed to be despatched away to be re-chromed and floor floor again to their specs. We additionally refinished the decrease tubes by hydro blasting them to attain a factory-like end. The internals had been serviced, and all new bushes and seals had been put in. The triple clamps had been hydro blasted, cleaned up, and fitted with new bolts and bearings. As soon as the body was again, we may begin becoming a few of these components to the bike.
THE POWERPLANT
Subsequent up was the engine. The underside finish and gearbox had been in fairly fine condition, solely requiring the circumstances and canopy to be Cerakoted gloss black and new bearings, seals, and a brand new rod to be put in. The highest finish had been bored to its final oversize, so we discovered the final sleeve accessible and had it put in and machined to OEM specs. A brand new piston and rings had been fitted, adopted by the meeting of the advanced energy valve system, which was then put in within the backside finish.
All through the restoration course of, we always referred to components fiches and pictures to find out which OEM cable administration elements we may order and what was lacking normally. After we acquired the bike, it had no air filter field or switch boot, so we needed to discover replacements. We miraculously managed to seek out one at an area wrecker, though it was in poor situation. After sprucing it and making use of a particular plastic paint to attain a uniform end, it regarded a lot better. The switch boot was hydro blasted and got here up effectively. As for the air filter cage, the one one we may discover was a 3D-printed duplicate from the US. It’s unbelievable what new expertise permits us to acquire, and it’s superb to see the proficient people who’re reproducing these components.
As soon as the engine was again in, we turned our consideration to the “UNI-TRACK” rear suspension system. Though I wasn’t round when it was in use, from what I’ve heard, it wasn’t essentially the most superb suspension system to trip on. Even after 36 years, it was nonetheless difficult to revive. We managed to seek out quite a lot of bushes and components wanted to deliver the hyperlink and shock again to their authentic state. Once more, we used pictures and different references to get the colours as shut as attainable for all of the elements and their fasteners. The shock spring was re-coated, and the physique of the shock was Cerakoted to match what we imagine to be the OEM colours.
THE NITTY GRITTY
Subsequent, we tackled the restoration of the swing arm, which isn’t a enjoyable course of and at all times presents points and issues it doesn’t matter what you do. After getting it as shut as we may to the unique end, we anodized it in a shade referred to as “impartial.”
The hubs had been stripped and Cerakoted gloss black, and new spokes and rims had been laced to them. Restoring the wheels is usually easy, involving the set up of latest bearings and re-zincing the axles. Instantly, it’s a curler once more. As a mechanic and restorer, it’s at all times thrilling to see smaller assemblies come collectively to carry out a typical process, even when it’s so simple as a mud bike with functioning suspension and wheels.
The subsequent problem was the tank… the place do I even begin with this one? The tank that got here with the bike was a horrible, cracked, outsized enduro tank that needed to go. We discovered a second-hand one from Texas, but it surely ended up being no good as a consequence of stripped threads and costing a fortune. Finally, we managed to discover a second-hand one regionally, however restoring it to our desired normal proved to be a battle. Happily, buddy of ours, who’s a grasp automotive painter, stepped in and restored it to its current superb state.
We used aftermarket entrance and rear guards for the bike, which was lucky since there are some actually poor vacuum-formed replicas on the market that don’t work effectively. Probably the most difficult half was discovering good duplicate facet panels. Nevertheless, a set of latest previous inventory facet and radiator shrouds unexpectedly grew to become accessible in France. Regardless of the eye-watering worth, we couldn’t resist and ordered them. Opening the manufacturing unit Kawasaki luggage they had been packed in felt virtually inconceivable, however as soon as we did and fitted them to the bike, it was love at first sight. It was a kind of sit-back-and-stare moments.
In spite of everything the joy subsided, we nonetheless needed to discover an exhaust for the bike. At that time, the one pipe that might look proper on it was an authentic one… “sigh.” So, we launched into a hunt and managed to seek out one on the East Coast of the US. It was in actually fine condition, so we had it despatched to our buddy Pete in California, who then shipped it over. Lastly, it went to Paul at Prime Pipe Works right here in Victoria to be restored to near-new situation. Paul is a wizard on the subject of all issues pipes and mufflers.
As soon as the restoration was full, it was time to fireplace up the bike. In the event you haven’t skilled the extent of compression an ’86 KX500 has, it’s arduous to grasp simply how brutal it’s. As a degree of comparability, a mid-’90s CR500 has a compression ratio of 6.8:1, whereas this monster boasts a compression ratio of 8.4:1. In the event you’ve ever began certainly one of these beasts, you recognize what I imply. As soon as it fired up, it emitted that unbelievable idle sound attribute of a big-bore two-stroke. It’s a sound that can not be adequately defined however is solely perfection.
In conclusion, I want to lengthen my honest gratitude to everybody who helped deliver this restoration collectively: Paul at Prime Pipe Works, Marshall Smith at Storage 11, Dao Radivo, Max Peters, Rob Kollosche, Pete Jesina, MTO Repairs, SP Moto Seats, Melbourne Anodising, Marty at VMX Decals/Stickers, and the superb guys at CMSNL.
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