Maintenance & Technical > KX500 Original

Carburetor to airbox boot

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KXcam22:
Hangtime,
  Your project is looking good.  Looking at those service honda photos (nice photos), the only thing I noticed was that they used "tabs" for the engine mounts.  For strength I think those should be more of a triangle shape like the stock mounts. A tab isn't very strong and puts lots of stress at the root where it's welded.  Also, Ive seen conversions where they used a round thinwall tube attached to the carb inlet to bridge a gap between the carb and the airbox boot.  It looks tacky if it's long but it almost invisible if it is 2" or less.  Hope this helps.  Cam.

hangtime:
I agree Cam, there is one photo that shows a tab that looks to be only about 3/4 in wide. Too much load over a small area. I think I'll cut out a longer triangular piece. Unfortunately the mount on the engine cases is narrower than the frame rails so I'll have to use a spacer.

KXcam22:
Hangtime,
  You could also dogleg them in a bit (L bend) to make up the gap rather than use a spacer, specially if you can get in close enough to tack weld them in place with the engine in (and bolted to) to hold them in the exact spot. In the end thought using a spacer is no big deal either. Cam.

hughes:
Hey, We all need to see more photo's of this bike your putting together.

kxs in oz:
Hi i am in australia and am also doing this conversion kx500 to 450f and have found if you get a 06 250f air box boot it will bolt straight onto the 450 air box and is lower than a 450 one so it will suit the 500 carby better all you have to do is make a adaptor to go on carby to air boot

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