KX Riders
Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: silviocross on November 17, 2012, 04:04:47 AM
-
Hi guys, I was looking for infos about aluminum frame conversions, and I just discovered this amazing forum!
I'm a 22yo student from Italy, and I'm modifying a KX250F with a CR250 engine.
The project is almost at an advanced stage, but I'm studying at about 200km from the bike, so I hope to finish it during christmas holidays.
Here you can see a log of the building:
http://progettosilvio.co.nf/?lang=en&p=240 (http://progettosilvio.co.nf/?lang=en&p=240)
I'd like to post here all the updates on the bike. Every suggestion is highly suggested!
-
Looks like you are doing a great job. The 2000 CR250 motor is a very good motor too.
-
Looking good! Whoever is doing the welding is doing a nice job!
-
Left radiator is almost completed.
It's 60mm shorter and 4mm thicker than the original one.
(https://lh5.googleusercontent.com/-WwFfw4Wq0IQ/ULR6dv7yKMI/AAAAAAAADEk/0klVqOcKZnk/s635/Schermata%2520del%25202012-11-27%252009%253A30%253A15.jpg)
-
This weekend I made the headmounts and the bottom brakets:
(https://lh3.googleusercontent.com/-CZqbdZDei_w/UMSLIHVWg-I/AAAAAAAADHQ/N3jUtF4t2Us/s640/12%2520-%25203.jpg)
(https://lh3.googleusercontent.com/-VTXJR_Aqdgo/UMSLIDeKeEI/AAAAAAAADHY/9y5J_VWImQs/s640/12%2520-%25204.jpg)
(https://lh5.googleusercontent.com/-y4yuyi7409c/UMSLINTcCwI/AAAAAAAADHI/NhmsTwIsDfM/s640/12%2520-%25202.jpg)
(https://lh3.googleusercontent.com/-XoHoglx1Wjg/UMSLIK66b_I/AAAAAAAADHA/Ed4odz-lfTg/s640/12%2520-%25201.jpg)
-
Finally, I finished the welding phase, and after a complete wash the frame is finished!
(https://lh3.googleusercontent.com/-AP_0tU1Ubrg/UNOCmDlDSKI/AAAAAAAADIo/e_4gn0iPc8M/s512/12%2520-%25205.jpg)
(https://lh4.googleusercontent.com/-n4ZT2laht5c/UNOCmIGwshI/AAAAAAAADIg/TBWUXGhkID4/s640/12%2520-%25204.jpg)
Tomorrow there'll be much more news.. :mrgreen:
-
That's coming along nice.
-
This weekend I made the headmounts and the bottom brakets:
(https://lh3.googleusercontent.com/-CZqbdZDei_w/UMSLIHVWg-I/AAAAAAAADHQ/N3jUtF4t2Us/s640/12%2520-%25203.jpg)
(https://lh3.googleusercontent.com/-VTXJR_Aqdgo/UMSLIDeKeEI/AAAAAAAADHY/9y5J_VWImQs/s640/12%2520-%25204.jpg)
(https://lh5.googleusercontent.com/-y4yuyi7409c/UMSLINTcCwI/AAAAAAAADHI/NhmsTwIsDfM/s640/12%2520-%25202.jpg)
(https://lh3.googleusercontent.com/-XoHoglx1Wjg/UMSLIK66b_I/AAAAAAAADHA/Ed4odz-lfTg/s640/12%2520-%25201.jpg)
Good design on the head stay! Engine can't rock forward or backward because of the triangle design. This takes a lot of the load off of the frame rails.
-
Thanks a lot!
Lunch-time update:
(https://lh3.googleusercontent.com/-dM_SrgnH1wc/UNRIfjG4uMI/AAAAAAAADKI/uEn8_haKGEM/s640/12%2520-%25205.jpg)
(https://lh6.googleusercontent.com/-80KTbAQyPb8/UNRIfgcHWeI/AAAAAAAADKc/VEk2WniXpYY/s640/12%2520-%25207.jpg)
(https://lh5.googleusercontent.com/-J7PFqJ1YaO4/UNRIfrAq_WI/AAAAAAAADJ0/PGosiylUU00/s640/12%2520-%25203.jpg)
This morning I finished welding the pipe, I hope to polish it later:
(https://lh3.googleusercontent.com/-W468XN8XRkA/UNRIfqfQK1I/AAAAAAAADJs/liMNBSPDG0U/s640/12%2520-%25202.jpg)
(https://lh4.googleusercontent.com/-bf3Te0OeBzo/UNRIfoXh35I/AAAAAAAADJ8/4Q-I8r-6ZEs/s640/12%2520-%25204.jpg)
-
Should have said something, I didn't know your were going back together so soon. I would have loaned you my magic tools.
http://www.youtube.com/watch?v=gRqUZrVwCpw
No tools in this one just magic.
(http://i126.photobucket.com/albums/p102/DrtBik/th_2008KX500AFreassemblypart2.jpg) (http://i126.photobucket.com/albums/p102/DrtBik/2008KX500AFreassemblypart2.mp4)
-
Should have said something, I didn't know your were going back together so soon. I would have loaned you my magic tools.
http://www.youtube.com/watch?v=gRqUZrVwCpw
hmmmm....gotta find a way to remove womens clothing with them there tools :-D
-
Should have said something, I didn't know your were going back together so soon. I would have loaned you my magic tools.
http://www.youtube.com/watch?v=gRqUZrVwCpw
hmmmm....gotta find a way to remove womens clothing with them there tools :-D
Ha ha, maybe you can use these, it's faster...
(http://cdn.pocketnow.com/html/portal/news/0000022771/x-ray.jpg)
-
dinner-time update:
ignition coil mount:
(https://lh4.googleusercontent.com/-1EmgBzYt-3M/UNSXkVZal3I/AAAAAAAADK0/n1blhu1qbNU/s512/IMG_20121221_161243.jpg)
(https://lh5.googleusercontent.com/-IFjmhVrfi0Y/UNSXzoCuLlI/AAAAAAAADK8/1z_jsjlvyeA/s640/IMG_20121221_170639.jpg)
this is the progress, atm:
(https://lh3.googleusercontent.com/-06ZleOvSglA/UNSYHQoNaZI/AAAAAAAADLE/dTSZnW5hmlA/s324/12%2520-%25201.jpg)
(https://lh3.googleusercontent.com/-dpyOUgicZtA/UNSYHRLxi8I/AAAAAAAADLE/B-tYMw_gXY4/s324/12%2520-%25202.jpg)
(https://lh3.googleusercontent.com/-oyPhPWwdhgk/UNSYHX-tMgI/AAAAAAAADLE/Yb7iCSsrIlA/s324/12%2520-%25204.jpg)
(https://lh3.googleusercontent.com/-nzMtZDa0aAA/UNSYHd89NNI/AAAAAAAADMU/RntHodV_UdQ/s324/12%2520-%25206.jpg)
(https://lh4.googleusercontent.com/-H1SkFdX2AQE/UNSYHbMmRYI/AAAAAAAADMU/VwQdBUw6rps/s324/12%2520-%252011.jpg)
-
today we're here:
(https://lh3.googleusercontent.com/-m2jr7BXbgjM/UNX74omfbZI/AAAAAAAADOg/1s7XHHuBprY/s640/IMG_20121222_160011.jpg)
(https://lh5.googleusercontent.com/-05iVaKZcy44/UNX74cVqlhI/AAAAAAAADOo/cUfiusrwSaA/s640/12%2520-%25204.jpg)
(https://lh5.googleusercontent.com/-78Vhq6DXWJg/UNX74egifeI/AAAAAAAADOk/j5UgeehWYBk/s640/12%2520-%25202.jpg)
(https://lh3.googleusercontent.com/-QC6G_-BMxKY/UNX74dIUwQI/AAAAAAAADOc/3eygoiBRs8Q/s640/12%2520-%25201.jpg)
-
So much work is needed yet, but tomorrow is time for a fist "debug" ride...
(https://lh4.googleusercontent.com/-SlRczTqNWDI/UNd-AQD_qRI/AAAAAAAADPY/OI0RgyIiNcA/s640/12%2520-%25201.jpg)
(https://lh6.googleusercontent.com/-qzYs9W0P06M/UNd-AeSFglI/AAAAAAAADPc/REPL6JgxX8E/s640/12%2520-%25202.jpg)
(https://lh4.googleusercontent.com/-dJ4Maes8ZrY/UNd-Aecz22I/AAAAAAAADPg/3k0zgdX3hNA/s640/12%2520-%25203.jpg)
(https://lh3.googleusercontent.com/-ws-B87iSXVA/UNd-Ae4yuhI/AAAAAAAADPk/rwomka1SCd0/s640/12%2520-%25204.jpg)
-
I can't wait to hear your post ride report :-D
-
nice work....looks great!!..now,get polishing that pipe!!! :-D
-
Get us some video when you get it dialed in, so we can hear it.
Looks like it will be fun.
-
If that motor was complete with carb and electronics, I'm betting its a 2001 not 2000. (The '01's came with the TMX carb) Jetting was supposed to be a PITA so everyone was switching back to the 2000 carb. (PWK A/S) Other than that the motors share the same components.
-
Hi everyone, I'm back from the very first ride.
First turn.... straight ahead. Oh right, engine braking is missing!
THE BIKE:
It's the same old kawa, the same riding position, same frame geometries and suspensions, but it looks like pretty different (obviously).
The engine weights just few kilos less, but the bike gives a great handle feeling. Can't wait to try it in the air. :wink:
I still need to find the right suspension settings, but time will come.
THE ENGINE:
men, this is weird. :-o
It has no bottom end, doesn't accept the upper gear so you always have to ride with the clutch in hand.
Essentially, it runs like a 125 with double the power. When the exhaust valve opens, the bike takes off.
For sure, my ride-style is still for 4 strokes and I've to change it for this new engine, but the powerband has to be smoothed, otherwise I can't ride it like I want.
So much work needed for better jetting it on the lower-end side (thanks RoostDaddy for the info about the carb, maybe I've to switch back too) and I've to short the final transmission a bit to reach the stk CR 250.
If this doesn't work, I'll have to try deeper changes.
But hey men, this is a pretty amazing bike! :mrgreen:
-
Thanks for the update!
Keep up the details.
-
Hi guys, many updates since my last post here.
I checked the engine and found that the powervalve was blocked wide open. That's why that ON-OFF behaviour on the first ride.
The custom radiator arrived:
(https://lh3.googleusercontent.com/-HFcLFIX-P4Q/UPBq0tm4sHI/AAAAAAAADSg/oEBWpsVTRQA/s512/13%2520-%25201.jpg)
(https://lh5.googleusercontent.com/-Wj1Ko19dolc/UPBq0r-6FBI/AAAAAAAADSM/ClqmmLHTmp8/s408/13%2520-%25203.jpg)
Then I bought a BR8ECM spark plug, 10mm shorter than a standard one to have much clearance with the tank:
(https://lh6.googleusercontent.com/-tz-6zVRkFo8/UPBq0lUrl1I/AAAAAAAADSM/DTu3_YGkxhE/s408/13%2520-%25202.jpg)
Lastly, I designed the new graphics, here you can see a preview:
(http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/68455_10200607435974849_184445981_n.jpg)
-
Very nice...who did the radiators if you don't mind me asking?...and price?
-
Very nice...who did the radiators if you don't mind me asking?...and price?
Radiators has been made by winner racing (http://www.winnerracing.com/index.html), it's a chinese factory but the quality is great.
They asked me 60$ for a std radiator, and 85$ for my custom one.
-
d**n that's cheap....big question here....how well do they fit/line-up??
-
I just bought the custom one so I can't tell for standard replacements, but mine is really perfect, every dimension correspond with those I gave them. In my opinion they're really good.
-
ok...thank you.
-
Refurbish a 10 years old engine is quite easy:
1 - remove the all Honda signatures
2 - sand clutch cover, waterpump and powervalve cover:
(https://lh4.googleusercontent.com/-dZ-P0l-e7T4/UQvAAA4kWWI/AAAAAAAADUc/4nGy87TjZ8o/s400/13%2520-%25201.jpg)
(https://lh5.googleusercontent.com/-d03NFKiP3Z0/UQvAAD-pREI/AAAAAAAADUc/Fe5m_zK3VeM/s400/13%2520-%25202.jpg)
3 - powder coat them
(https://lh5.googleusercontent.com/-YzhXC92D2sE/UQvAABapGKI/AAAAAAAADUc/7D5yzfLu_M0/s400/13%2520-%25203.jpg)
-
Step by step I’m going forward, many details are missing yet but it looks promising..
put the monster energy decals, they said..... :roll:
(https://lh4.googleusercontent.com/-i9iyGqoCBZg/USCus14sIwI/AAAAAAAADZk/rsAt7oItynQ/s640/13%2520-%25201.jpg)
(https://lh3.googleusercontent.com/-YRbjPhhYagM/USCus_OrTII/AAAAAAAADZw/ySxTKRTqmqs/s640/13%2520-%25203.jpg)
(https://lh4.googleusercontent.com/-gxOp9db8aBc/USCus2NMnQI/AAAAAAAADaU/XD6bowgvAfo/s640/13%2520-%25207.jpg)
(https://lh4.googleusercontent.com/-Q4nSd2tDCsc/USCus-NcSsI/AAAAAAAADas/s51II6Zo_8g/s640/13%2520-%252010.jpg)
(https://lh5.googleusercontent.com/-WKaRHPyR2qI/USCus4QZGtI/AAAAAAAADa4/tBU5diLU8Hg/s640/13%2520-%252011.jpg)
(https://lh4.googleusercontent.com/--zLgzLm7XmM/USCuswjsEGI/AAAAAAAADbQ/hYmQt5PctDU/s640/13%2520-%252013.jpg)
(https://lh6.googleusercontent.com/-wBC-GPF2PBQ/USCuszVKocI/AAAAAAAADZY/fqZPpUQvgsY/s640/IMG_20130217_110746.jpg)
(https://lh4.googleusercontent.com/-TmtvpvACLz4/USCusyycQHI/AAAAAAAADZc/d3dzGSEC6rU/s640/IMG_20130217_110819.jpg)
(https://lh3.googleusercontent.com/-JF7ZOyIt_Uw/USCus6x3rzI/AAAAAAAADaI/22h5hedWtcM/s640/13%2520-%25206.jpg)
-
Still missing the radiator guards, but it's ready!!
(https://lh3.googleusercontent.com/-VvPIiKnigcg/USkCoZ05uPI/AAAAAAAADe0/W85uNRRmOK0/s827/IMG_3282.JPG)
(https://lh3.googleusercontent.com/-FZFk8kvNASc/USkCqrRTScI/AAAAAAAADfE/4q-XawCpalc/s828/IMG_3285_6_7.JPEG)
(https://lh6.googleusercontent.com/-3sYT9W7j2VQ/USkC5ORWTFI/AAAAAAAADfU/84-3epNGcFE/s828/IMG_3287_8_9.JPEG)
(https://lh6.googleusercontent.com/-bGooLRYnyfU/USkC3xQaSyI/AAAAAAAADfM/fwV2aa3ujZU/s551/IMG_3288_9_9.JPEG)
(https://lh5.googleusercontent.com/--pzuD-pqoHI/USkDJAlgA4I/AAAAAAAADfk/oK_VOx8Dan0/s827/IMG_3291.JPG)
(https://lh5.googleusercontent.com/-Uh0sO1xdZz8/USkDjOGwiEI/AAAAAAAADgE/KQ7fdUBxmxM/s827/IMG_3297.JPG)
:mrgreen: :mrgreen:
-
Looks very good.
Now we need some pics showing some air time :-D
-
Nice looking bike.
Makes me think about how quick the Japanese manufactures were to shelf a good thing like the 2 stroke. Now the Euro manufactures pretty much have the 300cc market and I'm guessing decent sales numbers. There is a type of riding and racing where the 2 stroke is superior to the thumpers.