#motocross #dirtbike #race #sport
Nathan Alexander, who was the team manager at the Mucoff Honda team in 2021, was the mad scientist who brought the 2000 Kawasaki KX500 and 1994 Honda CR500 to life. He went one step further while resurrecting these beasts by making the KX500 a replica of Jeff Emig’s 1996 MXDN machine and the CR500 into a replica of Jeff Stanton’s factory 1992 CR500.
When Nathan first got these bikes, they were in bad shape. No surprise, they were over 20 years old and hadn’t had the best of care (the KX500 was in boxes). An old project bike is harder to get back together than a 1000piece jigsaw puzzle without the picture on the box to guide you. I have struggled many times with numerous unfinished projects in my garage. The only good thing about a box of parts is that it gives you a fresh perspective on the task ahead. It allows you to create the bike you want from the ground up.

Jamie Ellis at Twisted Development was a part of making this project come to fruition. He was the original owner of the box of parts and volunteered his expertise, his dyno and his race shop to get the bikes in running order. The two bikes took months to complete. Nathan and Jamie wanted the 500s to still have that oldschool feel with a touch of newage technology.

The biggest upgrades were to the front ends on both bikes with modern Kayaba forks that had been updated by Factory Connection. The Honda CR500 got AKit air forks from a 2018 CRF250 with EZE 22mm triple clamps from Australia (stock is 24mm). The front wheel and brakes were also off a 2018 CRF250. On the rear brake, Nathan used the stock CR500 caliper but took out the plunger and used CRF250style internals. The engine was rebuilt with the cylinder and head cleaned up and a 1.5mm bigger piston to erase all the previous wear and tear. The only part of the CR500 engine that wasn’t new was the crank; they are difficult to rebuild, and they aren’t available anymore. It was decided that since it had lasted 28 years, it was probably good to go.

Nathan decided to use 2002 KX250 twostroke forks and clamps on the 2000 KX500. The wheels were standard with updated D.I.D. rims and beefier spokes. The front brake used a standard caliper that is mated to a 2020 CRF250 master cylinder. The entire engine was gone through, with the cylinder and head being cleaned up.
Both of the bikes had Lectron carburetors, which Nathan assured us were extremely simple to use, and the jetting was spoton. Both bikes’ transmissions were treated with Sano Metal rim finishes, along with FMF bolton power, VForce reeds, SKDA custom graphics, razorsharp Pro Pegs pegs and Factory Connection suspension.

First, we want to thank Jamie and Nathan for resurrecting these relics of time. It was an honor to get in the saddle of the beasts. We loved riding these 500s much more than any factory bike or new production model. Some would say we are crazy, but after the hype of testing factory bikes wears off, they aren’t as fun to ride as you would think. Do we sound like a spoiled test rider? We are. MXA is numb to the fact that we get to test bikes for a living. Thankfully, this feeling has guided us to the bikes that bring pure joy. These 500cc machines made us grin from ear to ear.


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