KX Riders
Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: agentwilliams on January 27, 2013, 03:32:54 PM
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I'm new here and stoked to see the forums back up. Thanks to all of the people contributing.
Here is my project. 2010 KX250F and 1994 KX500.
The 250 was bought in Ohio on eBay and the 500 was bought near Indy from Cl. I'm in Saint Louis, but I got both bikes in 1 road trip!
Although it was bought under the description of "it ran when I parked it 8 years ago" the 500 is in need of a rod and is due for a top end and cylinder replating. It looks like it ran without premix. Other than that, it appears to be pretty low mileage.
The plan is to build it, refine it for a year, and race the BAJA1000 in 2014.
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Did you day the B word :-D
That would be some ride.
Take lots of pics and post often as we all like to see builds progress.
Thanks!
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Did you day the B word :-D
That would be some ride.
Take lots of pics and post often as we all like to see builds progress.
Thanks!
HAHA - yep- da "b" word! I saw your business link in your profile and will reach-out if I need something.
I'll keep up with build pics.
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I gutted my engine is gutted so the lump is lighter going in and out of the frame.
Surprises - The "new" cylinder needs plating... The lower rod bearing is toast. The cases need a small repair where it looks like the rod went - not too bad. Overall, not as bad as it sounds, but the cylinder is a real bummer.
I cleaned it up with elbow grease and detergent, but the aluminum is stained. I bought a bead blaster to clean up the cast parts. I'll wait until I get the frame finished to make it too clean.
SH is out of KX500AF exhaust so I'm thinking of cutting the inlet of the donor bike's pipe off (it's a thrashed FMF) to give me something to mock up clearances in the Y area.
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I did the same thing with my mock up engine.
Gutting them out makes a huge different when taking them in and out.
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I played a little with the engine and frame. Here are some loose mock-up pics.
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Looking good!
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You're off to a good start......can't wait to see what this thing ends up looking like 8-)
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How does the clearance look like from spark plug to tank? Im curious for myself as well since we have almost the same project going on :mrgreen:
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NGK BR8ECM
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Chuck Norris brushes his teeth with a kx500 conversion toothbrush..... :-D
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Progress at last!
I teamed up with my old moto-bro Ray from goldmedalwelding.com and made the brave cuts on the frame.
The stock "y" was re-used, jfab frame rails are in place. We will re-use the stock motor mounts, relocated for the K5 of course.
When he does the finish welding, i'll post some better pics. This man can weld!
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NGK BR8ECM
i use only this plug in my 250, 360, 500 ... its easy handling and on the big engines it gives the right clearance to the tank.. :-)
nice bikes on the first look, :-D ... its a little bad that the k5-engine is worn out, but new rod,piston crank bearings seals and plating and you´re back in business and it make sure, you have a great engine in the af-frame if you finish the projekt... :wink:
service honda use a light modyfied cr500 exhaust on their kx500af-bikes... you can buy a aftermarket cr500 pipe and weld the right kx500-flange on it for the cylinder-fitting . thats easier as cutting off and welding together the whole old k5-pipe ... :-D
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Thanks Motopunk. The CR pipe is becoming necessary with SH not having anything available for the last 3 months!
What year of CR pipe?
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Go with 89 to 01 cr500 pipes. Fits good on the 09-13 kx250f frames. I will try to post photos of how i welded my pipe to fit. Should be the same for you
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Thanks Motopunk. The CR pipe is becoming necessary with SH not having anything available for the last 3 months!
What year of CR pipe?
.. :wink:... all cr500 pipes from 1989-2001 will work. you must in first finding the right one for your needs at the desertraces ...
i used a cheap stock cr500 pipe and a new pro-circuit silencer for my bike ...and it looks a little bit like oem-style 8-)
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LundMX - thanks for the quick advice and the detailed build posts.
I referenced your build a few times to get mine in order.
I'm going pro circuit. For no other reason than the late 90's splitfire bikes are some of my faves. And I dig unplated pipes!
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LundMX - thanks for the quick advice and the detailed build posts.
I referenced your build a few times to get mine in order.
I'm going pro circuit. For no other reason than the late 90's splitfire bikes are some of my faves. And I dig unplated pipes!
i also love the unplated pro circuit pipes ... good decision :-D
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agentwilliams, glad i can help. In my build section i posted the test ride video from yesterday, the pro rider that is racing it for me is lovin it! you will to, its a great setup
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Small steps...
Got my drill bit for the swingarm bolt. Orderer my wossner piston and vesrah conrod kit. Pipe next paycheck. My cylinder will get replated when I get done mocking up.
Unfortunately my next work session is in 2 weekends.
This board rules!
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Progress today!
An old moto-x buddy, Ray of Gold Medal Welding, is a welding fool. He'll button up the motor mounts soon and I'll post pics.
We took a different route on the headstay. We used the stock KX250F head stays and fabbed tabs for the upper crossmeber using the brackets we cut off the frame. Plenty of tank and Carb clearance.
(http://i74.servimg.com/u/f74/17/34/90/63/headst10.jpg)
(http://i74.servimg.com/u/f74/17/34/90/63/headst11.jpg)
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Looks great!
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very good idea...thats what i always try, using as many of the oem parts as possible... :-)
cant wait to see more of your progress. :wink:
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I started a blog on the trip planning - if I decide to pursue sponsors, it might help. Mostly, it will just be fin to read later.
http://baja1000onthecheap.blogspot.com
I'll keep the bike related stuff coming here. I really can't wait to get the pro-circuit pipe on this thing. Works pipes are sooo cool. I can't stand it sitting on the bench!
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What is your plan for fuel??? Large tank??? Lots of stops???
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What is your plan for fuel??? Large tank??? Lots of stops???
Yes, large tank and lots of stops. Possibly an aux tank.
I'm not sure how far I can go on a tank yet, so that will determine how inventive we will get with fuel.
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Progress yesterday. Motor is locked in and pipe mods have started.
(http://i.imgur.com/agyTRHB.jpg)
(http://i.imgur.com/mpfa3Um.jpg)
(http://i.imgur.com/A5QG4SA.jpg)
(http://i.imgur.com/kF2dMlt.jpg)
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looking good!
that pipe looks like it was custom made it fits so cleanly in there! what PC model pipe is it?
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looking good!
that pipe looks like it was custom made it fits so cleanly in there! what PC model pipe is it?
Thanks,
It's a PC pipe from a CR500 It fits great, but it is very tight to the cylinder. I haven't decided how I am going to handle coolant hoses yet, but I'm sure it involves heat and a hammer. I used the neck off of the stock pipe and the pipe spring loops will be moved. It looks like all of the mounts will work!!! Here is the link to the one I bought - http://www.chaparral-racing.com/Product/pro-circuit-works-2-stroke-exhaust-pipe/997-WORKS.aspx?year=2000&make=HONDA&model=CR%20500R (http://www.chaparral-racing.com/Product/pro-circuit-works-2-stroke-exhaust-pipe/997-WORKS.aspx?year=2000&make=HONDA&model=CR%20500R) I do not endorse or work for this company.
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The Pro-Circuit pipe is big around the coolant pipe area. I had to do some denting to the pipe and move some coolant inlets/outlets. Here is the roughed in way we tackled it.
The coolant elbow that mounts to the cylinder is really a strange alloy. It was not easy to weld.
(http://i.imgur.com/8sq5jAs.jpg)
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Can anyone post, or point me to some pics of KX500 mounted radiators?
I bought the high-capacity KX500 radiators and am having a little trouble. It seems like there is a very small sweet spot between the lower triple tree, the cylinder head and the potential frame mounting points that I would like to hit.
Here are some of the details I am struggling with:
- The angle of the radiators vs the angle of the downtube of the frame (before the Y).
- The upper crossover radiator tube. Where it goes through the frame.
- Mount locations.
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Are you using stock or oversized tank?
I have a 07 kxf250 frame with 98 kx500 engine.
Mine radiators follow the angle of down tube. Are special radiators from 04 rmz250, there are 2 inch longer than stock.
Crossover tube: As straight as possible where there's room.
For mounting: I made new points on the frame and for the radiator guards I used a self made "worksconnection" like radiatorguard.https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#5988730708326009330 (https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#5988730708326009330).
I like your coolant elbow btw.
Dutchie
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https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#5988730708326009330 (https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#5988730708326009330).
Dutchie
Thanks! I am going to run a bigger tank, but that's for an other day.
I can't get the link to work, but I'm dying to see your radiator work.
Can you repost?
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https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#5988730708326009330 (https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#5988730708326009330)
I made it public now.
I asked for the bigger thank because I bought one later and it doesn't fit for now.
On the left the radiator hits my ims tank and if i lower it it hit the exhaust. Planning to use different radiators in the future.
Dutchie
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https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#5988730708326009330 (https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#5988730708326009330)
I made it public now.
I asked for the bigger thank because I bought one later and it doesn't fit for now.
On the left the radiator hits my ims tank and if i lower it it hit the exhaust. Planning to use different radiators in the future.
Dutchie
Great conversion, the pics help - Thanks.
I think I can make these oversized kx radiators work. They are thicker than stock, but much shorter than kx250f radiators. It's gonna take a little fiddling, but I still think they will fit. The capacity is good for my use.
I have done IMS and Clark in the past. I'm thinking about trying the acerbis 3.7 gal. Their replacement panels have always had OEM fit and finish (or close to it).
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d**n that's one bad a$$ silencer...step up to the plate and park a homerun with that thing.
(http://i895.photobucket.com/albums/ac152/foxx4afoxx2/Afb0089_zps4536f388.jpg) (http://s895.photobucket.com/user/foxx4afoxx2/media/Afb0089_zps4536f388.jpg.html)
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:-D LOL
I think it could be street legal :lol:
O wait it´s mine :roll:
I even have been thinking of running two of these like the crf´s did.
Dutchie
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:-D LOL
I think it could be street legal :lol:
O wait it´s mine :roll:
I even have been thinking of running two of these like the crf´s did.
Dutchie
nice!!...how crazy would that look and sound?
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It would look real cool only I think there would be NO sound.
Many people have trouble hearing me now.
Only have to find a rearleft numberplate that sticks out for space for the second silencer.
Dutchie
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d**n that's one bad a$$ silencer...step up to the plate and park a homerun with that thing.
(http://i895.photobucket.com/albums/ac152/foxx4afoxx2/Afb0089_zps4536f388.jpg) (http://s895.photobucket.com/user/foxx4afoxx2/media/Afb0089_zps4536f388.jpg.html)
the rhino-silencer looks very similar to the big spes cr500 silencers...
i use the pro circuit r304 factory sound silencer.. great look , powerful sound ..perfect for me... :-)
(http://img.webme.com/pic/d/der-motopunk/foto0142.jpg)
dutchie .. i know what you plan . you will sneak from behind that nobody could here you coming... :wink:
some supermoto-guys are wrapping also their pipes for more silence-effekt...
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D*#@m you have me.
Rino is made by Doma(SPES, Slechten), thats wy I wanted this one. Have Always liked those big SPES silencers.
For the sound two stokes ar better and with supermoto sound is a big probleme, thats wy the use double silencers.
He Motopunk, you have a KX506 licenseplate on the trailer 8-)
Dutchie
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D*#@m you have me.
Rino is made by Doma(SPES, Slechten), thats wy I wanted this one. Have Always liked those big SPES silencers.
For the sound two stokes ar better and with supermoto sound is a big probleme, thats wy the use double silencers.
He Motopunk, you have a KX506 licenseplate on the trailer 8-)
Dutchie
:-D... i know this fact that doma , rino and spes are quite the same make with decent diferences. on the dyno are the complete exhausts near by each other in direct comparing...
my licence-plate is kx500 .. :-D you see a bolt where the white cap was loose...
on my newer car i have also kx500 plate... 8-)
(http://media3.nb-town.de/nb-town/user/240290_0BwryZ4tijTxLN9.jpg)
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Landkreis Uckermark KX500
In Holland we can't pick plate numbers :cry:
Looks sweet
dutchie
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Landkreis Uckermark KX500
In Holland we can't pick plate numbers :cry:
Looks sweet
dutchie
here in germany normally we also cant pick fantasy-plates, but i questioned if this plates would be free and got it... live is to short to have no exclusive things like that... 8-)
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Radiators mounted up today. Need to get hoses and angle inlets/outlets, but they're mounted!
I used the aftermarket ones for the KX500.
I test-fit my acerbis oversized tank and it's not gonna work. I guess I need to try the IMS.
I would be wrong not to plug www.goldmedalwelding.com for the fab work thus far.
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Progress Pics:
(http://i.imgur.com/ZAWiLs2.jpg)
Linkage bearings are out - why it looks so tall.
(http://i.imgur.com/hqKOemX.jpg)
(http://i.imgur.com/Pu9DvCi.jpg)
(http://i.imgur.com/Z0vpXRA.jpg)
(http://i.imgur.com/atxgsXC.jpg)
(http://i.imgur.com/n5o2Qgh.jpg)
Pipe and radiators are insanely well fit.
Give me a break on the dirt - I know it needs to be detailed, but the frame is getting cryogenic treatment.
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looks good, liking that unfinished pipe!...nothing wrong with it being dirty 8-)
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Looks great!! Like the DLC forks, works exhaust, 2010 frame, just everything.
Dutchie
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looks great... time to finish the motor and give us a ride report... 8-)
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I bought a running 01 KX500 today for a spare engine. It is much nicer than the grenaded '94 I started with. Dan from Sidney, IL is an honest dude and cut me a fair deal. He works at a shop called Mid State Cycles. http://www.midstatecycles.com/ (http://www.midstatecycles.com/)
It's nice to cross paths with people who don't suck. Odd that they usually are moto-people.
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It's nice to cross paths with people who don't suck. Odd that they usually are moto-people.
it's so true...same with snowmobilers.
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I am running large volume KX500 radiators with stock style flow.
For hoses I'm rolling the dice on internet purchases again.
Mishimoto has great deals on kits, so I bought a few.
http://www.mishimoto.com/kawasaki-silicone-hose-kit-powersports.html (http://www.mishimoto.com/kawasaki-silicone-hose-kit-powersports.html)
I bought a KX500 kit, a CR125 kit and a RMZ450 kit. I feel comfortable gambling with $60 in hoses since I am pretty sure my local auto parts store will charge $10 a hose, they aren't as cool as silicon hoses and I don't want to dig through their disorganized racks for 3 hours.
I'll let my fellow KXRIDERS know if I can make it work and what I end up using from the 3 kits.
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I am running large volume KX500 radiators with stock style flow.
For hoses I'm rolling the dice on internet purchases again.
Mishimoto has great deals on kits, so I bought a few.
http://www.mishimoto.com/kawasaki-silicone-hose-kit-powersports.html (http://www.mishimoto.com/kawasaki-silicone-hose-kit-powersports.html)
I bought a KX500 kit, a CR125 kit and a RMZ450 kit. I feel comfortable gambling with $60 in hoses since I am pretty sure my local auto parts store will charge $10 a hose, they aren't as cool as silicon hoses and I don't want to dig through their disorganized racks for 3 hours.
I'll let my fellow KXRIDERS know if I can make it work and what I end up using from the 3 kits.
I bought 4 sets of different hoses too. Kx500, KX450F, CR125, and KTM450. I figured I'd be loosing money if I didn't jump on it.
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Alward is selling me a 100w stator units. I have a set of LED lightbars from Rigid industries good for 7000 Lumens.
I really can't wait to see how these things work!
http://www.kxriders.com/forums/index.php/topic,8234.0.html (http://www.kxriders.com/forums/index.php/topic,8234.0.html)
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Airbox is done. Engine is built. Wheels are in. Graphics are to print. Parts are ordered.
Here is the '10 KX250F airbox with Twin Air Power Flow Kit, Carbon Adapter and '01 CR250 boot:
(http://i.imgur.com/9s8KHPg.jpg) (http://imgur.com/9s8KHPg)
(http://i.imgur.com/JwMcTZP.jpg) (http://imgur.com/JwMcTZP)
(http://i.imgur.com/bMoPhFC.jpg) (http://imgur.com/bMoPhFC)
It is all sealed with HV350 from Valco, I can't say enough good things about this stuff. It's like hot glue for men.
http://www.valco-cp.com/hv-350.htm (http://www.valco-cp.com/hv-350.htm)
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On my 2008 450F/2004 KX500AF SH the top bladder housing on the rear shock rubbed on the top nut of the air box boot housing. SH had ground the nut down for clearance but it wasn't enough. Made some mods and some JB weld on the shock housing for insurance and cured the problem. When it comes time to build a new air box or do repairs I'll probably use rivets for some extra clearance. Your build looks great!
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When it comes time to build a new air box or do repairs I'll probably use rivets for some extra clearance. Your build looks great!
Thanks!
Those are button-head allen screws. Rivets tend to loosen over time. I can't deal with air leaks in BAJA!
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Ummmmm BIGTIME HEADLIGHTS! Frame mounted so they don't turn with the bars.
Thanks to Rigid Industries - these things are unreal.
(http://i.imgur.com/DZNIU3j.jpg)
(http://i.imgur.com/OoOY7Dr.jpg) (http://imgur.com/OoOY7Dr)
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http://baja1000onthecheap.blogspot.com/
(http://i.imgur.com/C8CWDmz.jpg) (http://imgur.com/C8CWDmz)
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Custom Baja tough titanium skidplate.
Get 2 guys like Larry from Allied Precision Arms and Ray from Gold Metal Welding together and the magic happens.
Less than 3 weeks until we leave for Baja!
(http://i.imgur.com/J8Ks7zJ.jpg)
(http://i.imgur.com/XzKTWFk.jpg?1)
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that thing's lookin pretty stout!...how much does it weigh?
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I notice on one of the pics the front brake hose is on the out side of fork leg , unless you want it to hook on something I would put it back on the inside were it belongs , hate to see it get snagged on something and go for a soil test.
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Skidplate weighs 2lbs 6oz. Waterpump and frame rails are very well protected.
KXDino, the pics you are looking at are complete mock-up pics, brake hoses will be proper.
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First Ride Report:
16:42 gearing is awesome, I can't imagine riding this thing with stock gearing... It has torque for miles.
I'm running a 168 main, a 55 pilot, a #7 slide and a N82M Needle.
It has symptoms of running a little lean in the midrange: Momentary high idle when off the gas when hot, etc. The plug looks pretty good, just a little lean. Race gas and dropping the needle clip helped, but it's not perfect.
Next steps- I'm going to test a 58 pilot and maybe move up to a 170 main.
Rigid Industries LED lighting is amazing. The tiny taillight and the spaceship headlights are crazy. I was too busy riding to take pics, but will take some before we destroy this bike in Baja.
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Officially ready for Baja. Follow our gps dot on score-international.com 236x is our number.
(http://i.imgur.com/5ajC1Fd.jpg)
(http://i.imgur.com/J0U4OZK.jpg)
(http://i.imgur.com/xLAAWVz.jpg)
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Phenomenal.... Nice job!
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I noticed farther back in the forum you were talking about gas tank and lots of stops. I see the oversized gas tank, but if you are looking for better fuel mileage and performance buy a lectron.
If you are familiar with them you will know they don't need to be rejetted once set and they also help out fuel mileage quite a bit. I have one on my kx500 and can't say enough great things about them.
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it's unique...that's for sure!
good luck in the Baja!!
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:cry: :cry: :cry: I'm so jealous at you, for the bike and BAJA.
GO have fun and live the dream of many of us :-D :-D :-D
Dutchie
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(https://lh3.ggpht.com/DfsMb72tUN-jvTsDuHCafUvJXVoIqKW_7KiYx9Hk_cWNc7a8nOI3FQc5QsmWO5_oSbmt=s111)
The seat looks comfie!
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Kris is at race mile 463 as of 0836 hrs!!!! Either has not checked in or transponder not working or not updated. Hope it is going well
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Kris is at race mile 463 as of 0836 hrs!!!! Either has not checked in or transponder not working or not updated. Hope it is going well
Anybody know the out-come of this sweet bike in the Baja
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Chatted with Kris a little via text, he said they made it to race mile 495 and had an overconfident rider in over his head and timed out. The bike ran great with no problems. He got to park it in the Rigid Industries tent and Malcom Smith and Jeremy McGrath both commented on the quality of the fabrication. He had a lot of fun and wants to do it again but not sure if life will allow this next next year to happen but has the bug bad to do it again.
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Thanks for posting info Alex. Here is the official wrap-up:
http://baja1000onthecheap.blogspot.com/2014/12/wrap-up.html (http://baja1000onthecheap.blogspot.com/2014/12/wrap-up.html)
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Thanks for posting info Alex. Here is the official wrap-up:
http://baja1000onthecheap.blogspot.com/2014/12/wrap-up.html (http://baja1000onthecheap.blogspot.com/2014/12/wrap-up.html)
cool pics!!...any video, so we can all hear that thing running....or rippin through a check-point?
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Sorry to hear it ended sooner as plannend. Like you said it's 495 miles more than 99% than othet people.
I'm still verry jealous of doing that dream of many.
And cool to see big names like the AF :-D
Dutchie
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Here are the videos I could find:
Go to 36:20 to see the start interview:
http://www.ustream.tv/recorded/55368707 (http://www.ustream.tv/recorded/55368707)
Go to 17:28 to hear it take off (spinning) and see me rip a wheelie!
http://youtu.be/gRdA9vubBJc (http://youtu.be/gRdA9vubBJc)
http://youtu.be/LeqxahlSaEI (http://youtu.be/LeqxahlSaEI)
Here are some short clips from random trailside videographers
http://youtu.be/e217_SN8az0 (http://youtu.be/e217_SN8az0)
http://youtu.be/5tWD3UTIM8k (http://youtu.be/5tWD3UTIM8k)
http://youtu.be/hZplMMUs3ig (http://youtu.be/hZplMMUs3ig)
http://youtu.be/1k69izf6UBM (http://youtu.be/1k69izf6UBM)
http://youtu.be/hZplMMUs3ig (http://youtu.be/hZplMMUs3ig)
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NICE!!...that thing sounds crisp!
thanks for sharing those pics and vids!
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The baja recap video:
http://youtu.be/AD4rOqGszUs (http://youtu.be/AD4rOqGszUs)
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The baja recap video:
http://youtu.be/AD4rOqGszUs (http://youtu.be/AD4rOqGszUs)
awesome footage!!...thanks for posting it!
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The baja recap video:
http://youtu.be/AD4rOqGszUs (http://youtu.be/AD4rOqGszUs)
JESAS I did not think you would last the first 5 minutes :-o :-D
taugh u had done a collerbone done at that 4.50 crash, and missed that corner earlier :-D
Well Done that kx sounded great
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hahaha - yeah, that mudhole was pretty unexpected.
I've broken a collarbone, it's really easy to do.
I was wearing a chest protector with shoulder plates, and an Alias neckbrace.
Most importantly, I had luck on my side that day.
I learned quickly to slow down when I saw a crowd.
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That was so cool when Malcolm Smith complemented your bike. I imagine that made you smile for a large portion of the race.
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could be why he ran off the course a few times in the beginning :lol:
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could be why he ran off the course a few times in the beginning :lol:
I probably wouldn't have started on time, because I would have been trying to show my bike off to Malcolm. :-D
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my hat is off to you ! That is a great video.
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Hey agent williams nice bike man.
I read earlier that you are from St Louis are?
Ever ride St joe park.
I'm from Patton Mo so you are actually not that far from me