Maintenance & Technical > KX500 Original

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demographic:

--- Quote from: Good on July 18, 2007, 09:58:12 AM ---Just kiddin' but here's your gusset manual!  (or mine anyway) :wink:

http://dirtrider.net/forums3/showthread.php?p=1139881

--- End quote ---

Errr, after looking through nine pages of very interesting KX500/250 hybrid stuff I am struggling to find any pictures of gussetted 500 frames.

Nice thread all the same though.

BigGreenMachine:
The "just kiddin but" opening line should have told you better.

The basics that I know are to gusset corners and triangulate as much as the frame without going overboard.  I'm going to brace corners of where I mated the two frames and some of the subframe.

I'll post pics here when I'm done.

Platypus:
I am not familiar with what to gusset but I do know that it helps to complete all the welds.  If you look at the 500 frame a lot of the welds are incomplete and that is why we break pipe mounts so easily.  I hope that helps you get started.

BigGreenMachine:
Another good point thank you.

I've also seen someone do a custom pipe hanger mount then fill it with liquid gasket to act as a damper to kill the mount breaking vibration. Will be doing the same.

Platypus:
I will add the couple other things "I think" they would do or "have heard" they would do. 
Balance crank and longer clutch actuator lever.  I'm sure there are a couple I forgot and plenty I have never heard of.  I think Arigato has pics of the pipe mounts filled with RTV.  Also, I read it is a good idea to put  a bead of RTV around the o-rings prior to mounting your pipe.  If I remember more I will post them.

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