KX Riders
Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: LundMx on March 01, 2013, 07:34:55 AM
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Well I am a newbie to KXRiders.com I have spent time on other forums with my last build a cr500afc. Now im going to be tackling this ebay find here (http://i1358.photobucket.com/albums/q766/Clint_Lund/09kx250f1_zps2b0f9fbb.jpg)
It is missing the rear shock and sub frame and gas tank, i have everything else and scored it off ebay for $500.00.. not a bad start!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/09kx250f_zps3a3ae118.jpg)
it arrived last night 2/28/2013!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps962011fe.jpg)
And here is the Donor bike! 1988 kx500!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsfb10e0a7.jpg)
any help will be appreciated as i tackle this endeavor, I.E. need help with air boot choice, stator flywheel choice and mouting "of Course!"
LETS GO!!
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Looks like you're off to a good start! I'll be watching this thread in progress.
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Welcome. I have a similar project going, but I started with more of a 2011 250 and less of a 1994 500!
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The motor isnt making sense to the year, im thinking its newer than the frame.. Can anyone tell me the year of the motor? Heres a picture of the engine code (http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsb849a0fc.jpg)
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lookin like an 88 motor....scroll down to Sandblasters post for engine VIN's.
http://www.kxriders.com/forums/index.php/topic,6492.0.html
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Welcome. I have a similar project going, but I started with more of a 2011 250 and less of a 1994 500!
agentwilliams do you have any pics on you conversion yet? tips ect?
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lookin like an 88 motor....scroll down to Sandblasters post for engine VIN's.
http://www.kxriders.com/forums/index.php/topic,6492.0.html
thanks @foxx4beaver i would have to agree with you. Thanks for the info
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you're welcome...lookin forward to seeing this build. :-)
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Anyone know if the 88 kx500s where good motors? I heard that from 1988 on the didnt chance much so i figured i was in the clear with it... Thoughts?
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agentwilliams do you have any pics on you conversion yet? tips ect?
I haven't started cutting yet so I can't give any hands-on advice for the swap. I gutted my engine to make it lighter as I do the frame mods.
The internet is full of advice, but you can tell pretty quickly who's actually done it and who is recycling garbage advice that might not be accurate (this is not a shot at kxriders!).
I'm lucky to have a friend who is a award winning welder/welding inspector, so my advice is to team up with someone like that!
Service Honda is hard to get a pipe from. They don't order large batches, so it's tricky.
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I was just going to custom make a pipe because i've heard that about service honda
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Well as on last night i got my engine all gutted. And im getting some nice new add ons in the mail for the build! Brand new oem crank
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps41bf917b.jpg)
Brand new hinson clutch assembly!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps7ce310bb.jpg)
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that basket's lookin sweeeeet!
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Bikes look good, and should make a great conversion. The 250f may be an 11 but the forks are for sure not off an 11, the 11 had the titanium nitrade coating on the fork tubes and had the spring adjuster on one fork and the compression on the other, both were anaodized blue, in fact they look to be KYB from an 04-05, 06 on used Showa forks and they looked different. Those forks will probably work better than the 11 forks, since the 11 only had 1 spring you may not have been able to get a heavy enough one
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Bikes look good, and should make a great conversion. The 250f may be an 11 but the forks are for sure not off an 11, the 11 had the titanium nitrade coating on the fork tubes and had the spring adjuster on one fork and the compression on the other, both were anaodized blue, in fact they look to be KYB from an 04-05, 06 on used Showa forks and they looked different. Those forks will probably work better than the 11 forks, since the 11 only had 1 spring you may not have been able to get a heavy enough one
Yea I knew that going in purchasing the bike.. "Sadly" he did include the forks from an 08 that are the ones pictured.. i found some with tripple clamps on ebay and bought those they are off a "2010 kx450f" and should bolt right on
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Bikes look good, and should make a great conversion. The 250f may be an 11 but the forks are for sure not off an 11, the 11 had the titanium nitrade coating on the fork tubes and had the spring adjuster on one fork and the compression on the other, both were anaodized blue, in fact they look to be KYB from an 04-05, 06 on used Showa forks and they looked different. Those forks will probably work better than the 11 forks, since the 11 only had 1 spring you may not have been able to get a heavy enough one
Yea I knew that going in purchasing the bike.. "Sadly" he did include the forks from an 08 that are the ones pictured.. i found some with tripple clamps on ebay and bought those they are off a "2010 kx450f" and should bolt right on
I would stay with the 08 Showa forks, and try to find a shock off a 250f as well, I have taken the KYB's off and installed Showa on my AL framed 500, personally I like the Showa's better than the KYB, in fact that is a mod alot of serious racers do/did to their 450's, the 12 450 forks are pretty good, not sure how the 13's are going to be, ours has sat for a couple of months and didn't lose any air.
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thanks for the info! your making be feel better about substituting for the time being even if it be permanent. i was going to get a rear shock from the 09 kx450 just because a heavier spring :|
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If you do not mind me asking, where did you find the Hinson basket?
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If you do not mind me asking, where did you find the Hinson basket?
Well its a long story, but to cut to the chase, this bike is going to debut at this years pro nationals at glen helen raceway piloted by Pro rider Shawn Wynne, i have solicited the bike for sponsors and paul from hinson sent me the clutch kit. I can find the part number for you if you like!
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When I called Hinson, the response I got was they are discontinued. I think you need 2, one for a backup, and it can go to me.
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I just got the email back from Paul, he said yes they are no longer produced but still in rotation through a couple company's that still have them in n.o.s. "new old stock" he said he would find me a back up if i broke the one i have but then assured me that would be quite a feat!
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I have some more sad news for you, the forks pictured, as I said previously looked to be 04-05 250f, they are in fact of that vintage, they were also used on the 250 up to 07. Looked at my 08 Showas, they are different, yours are KYB.
Sorry.
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interesting, i know it says on the bottom aluminum piece at the bottom of the fork. now you have me interested, im going to check it out when i get home :/
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I just got the email back from Paul, he said yes they are no longer produced but still in rotation through a couple company's that still have them in n.o.s. "new old stock" he said he would find me a back up if i broke the one i have but then assured me that would be quite a feat!
I've just been assembling my engine and noticed that it has a Hinson clutch basket. So I started having a closer look at things. The primary drive gear is 16mm wide. The teeth on the basket are 12mm wide. Yet they only engaged about 11mm. Seems odd having such a strong primary drive gear and waste that strength by not using iT and also not permitting the clutch basket engage the full width of its teeth. Has anybody else noticed this?
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I just got the email back from Paul, he said yes they are no longer produced but still in rotation through a couple company's that still have them in n.o.s. "new old stock" he said he would find me a back up if i broke the one i have but then assured me that would be quite a feat!
I've just been assembling my engine and noticed that it has a Hinson clutch basket. So I started having a closer look at things. The primary drive gear is 16mm wide. The teeth on the basket are 12mm wide. Yet they only engaged about 11mm. Seems odd having such a strong primary drive gear and waste that strength by not using iT and also not permitting the clutch basket engage the full width of its teeth. Has anybody else noticed this?
ill check that out on my side when i go to assembly
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I extracted the "y" peice from my down tube today.. It came out pretty dam good i think!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps552cd770.jpg)
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So i made more progress today :lol: i made my measurements for the cut to move up the "Y" piece, so check it!!!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsc57768be.jpg)
I realized that i needed to cut out A LOT!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps804c39d6.jpg)
But after a lot of trimming slowly and precisely I finally got a fit that was like a glove!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps1598a6be.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps576b0108.jpg)
And what do ya know :lol:!!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps04466873.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsb707e0bb.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps669a4119.jpg)
So this weeks challenge is going to be bending the square tubing for the engine cradle, i need to make some more mounts obviously, but i smell premix in my soon future!
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almost like it was ment to be :-o
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Hey motorad, is jfab still making products? Im going to need help with these frame rails
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Hey motorad, is jfab still making products? Im going to need help with these frame rails
last I checked.... You have to call him at the shop though.
His phone number is at the beginning of any of his posts in the vendors section.
Report back
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yea, I'll try to get ahold of him. I had to jump ship on the fabricator I had been using for this project and now im totally up creek without a paddle. :? :x
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So i made more progress today :lol: i made my measurements for the cut to move up the "Y" piece, so check it!!!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsc57768be.jpg)
I realized that i needed to cut out A LOT!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps804c39d6.jpg)
But after a lot of trimming slowly and precisely I finally got a fit that was like a glove!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps1598a6be.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps576b0108.jpg)
And what do ya know :lol:!!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps04466873.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsb707e0bb.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps669a4119.jpg)
So this weeks challenge is going to be bending the square tubing for the engine cradle, i need to make some more mounts obviously, but i smell premix in my soon future!
Listen ... like dad in mom ... (French-speaking) Sorry ...
Good idea, doing the edges V before the weld.
équiliber also pin at the top of Y, square
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So stoked!!!!! Sponsors are really coming through on this build for us! Thanks so much Mika Metals, T.M. Designs, DNA Wheels, DT1 Filters, CTO goggles, Tamer holeshot devices, and everyone else that has helped get it this far.. Final fabrication and welding starts next wednesday!!!!!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsf36672e7.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps652de745.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpse48f06ab.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps98ab1bb0.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps404de695.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps2b8e35b0.jpg)
Stay tuned! :roll:
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Going to look gash with the original engine mounting holes still on the "Y". Plus you have an extra weld and heat cycle doing it that way. Will you be heat treating the frame once it has been welded?
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The holes were removed from the y piece and smoothed over.. Yes the frame will be re-heattreated after fabrication, my friend who ownes a powdercoat company is going to do it for me. Does anyone know how hot to treat it at and for how long?
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That's a a good idea re heat treating. I also have a friend who does powder coating. It's the one thing that worries me. Now that the engine is in and things going back on, the frame rails look rather small. Not very confidence inspiring. I'm kinda wishing I'd just bought a used SH bike sometimes. Although frustrating at times, it is rewarding over coming some of the problems...
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SO WE MADE HUGE PROGRESS LAST NIGHT!! :beertime: (http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af2_zpsc2d1eeb1.jpg)
prepping the "Y" piece for welding
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af3_zps541a9b17.jpg)
fit like a d**n glove!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af6_zpsf6356f46.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af4_zpsa34da0c4.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af1_zpsc4c7feac.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af8_zps532a3559.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af12_zps09752024.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af11_zps56b1243a.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af10_zps4bddd2f8.jpg)
time to start bending tubing!!!!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af9_zps5e53c051.jpg)
The Rails and mounts fit perfectly!!!! :mrgreen:
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af13_zps8ca34e4c.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af14_zpsce355e9d.jpg)
tonight we weld it all together and start on the head stay! (Stay tuned!)
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Looking good!
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those radii on the rails turned out great! i got a shop to do mine that had a HUGE $$$ bender and mine's got more creasing than that. nice fitment there.
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this is the bender we used : http://www.jd2.com/p-42-model-4-bender.aspx its about a $1200.00 bender
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I have the JD2 model 3 bender, it does a nice job, the benders are the cheat part, the dies are $300+ depending on the size. I used the 1" radius tubing, it ended up looking factory.
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So more progress made once again! check it out! :mrgreen:
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps1f0f74b0.jpg)
weld time!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsc3531f0e.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps4f427dba.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps6bd92308.jpg)
TIME TO MOUNT THIS MOTOR!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps66515651.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps9a2342e4.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpse9efaaf5.jpg)
TIME TO MOUNT THE FRONT OF THE MOTOR
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpse02973b8.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps9acc5da7.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpse4c362ce.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps9cf85516.jpg)
LIKE A GLOVE!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps57af2617.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps981c50c1.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps81c08f09.jpg)
AND TONIGHT WE START ON THE HEADSTAY AND PIPE!
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Excellent progress.
Great job!
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Ran into a snag, and a big one at that! the kx250f radiators are too long and hit the "Y" piece... need shorter rads.. any suggestions on where to start?
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Tonight we got started on the final stretch of the motor mounting
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps771df472.jpg)
The head stay came out super solid!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsa2834a78.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsce4c8fde.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsf520c3ec.jpg)
And now to take 1/2 kx500 pipe and 1/2 cr500 pipe and make one!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsc7ff2ddf.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps6c773787.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps063f43df.jpg)
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real nice work... 8-)
the weld seams look like a dream ... :-)
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Thanks @Motopunk! The guy who is welding it used to work for a racing manifold company doing all the intake manifold welding.. Guy is super tallented!
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Beautiful welding!
Yes, the radiators are a bit of a pain. Many people have used many combinations. The right side one off the 250 will work fine but the hose connectors will need rotating. It's th left that is the problem.
I bought a new, standard set of KX500 radiators, cut all the brackets off, and started from scratch. This way, I know that I have the right amount of cooling fluid etc. And the left one is not too long. I've also used the standard plumbing as well. I have a 2013 Gasgas 300 enduro ( it's very quick!), and it's exactly the same. ie The rads are plumbed in series. No point in over complicating things...
Looks like a 450 frame you're using?
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Brooksie, i found that out today, the kx500 rads look like i can make them work then just make another mount to the radiator shrouds.. This is a 2011 kx250f frame not 450f.. Fits good!
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Yeah, you'll work it. I've used the standard 250 screens with brackets welded on to the rad so the shrouds bolt through the rad into the screen just like stock. You'll have to shorten the left one a little, but it all works nicely.
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More big things today.. I mounted the fresh new Factory connection suspension, i got the forks from an 09 kx250f and same with the rear shock
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps39949cb3.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps1d31cfe3.jpg)
And i finally started assembly on the motor and got it installed
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsb028cb1b.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsa642c424.jpg)
Spark plug clearance is not going to be an issue
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsd29799f4.jpg)
And i got the pipe welded together and fitted!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps2aa132d4.jpg)
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Looking really good.
If you didn't modify the tank then the 2011 tanks must sit higher in the frame then the 2007.
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I got the tank from a 2009 kx250f, last year of the carburator... Looks like it will work perfect :mrgreen:
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09 kx450 used KYB forks.
those look just like the showas off my 250f
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I got the tank from a 2009 kx250f, last year of the carburator... Looks like it will work perfect :mrgreen:
you could also use a shorter sparkplug for some clearance under the tank ...i use the ngk br8ecm ... they´re exlusively made by ngk for the ktm sx 360 and sx 380.
... good job, will be a nice bike... 8-)
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09 kx450 used KYB forks.
those look just like the showas off my 250f
i would think they would be the same
I got the tank from a 2009 kx250f, last year of the carburator... Looks like it will work perfect :mrgreen:
good to know! i might pick some of those up! thanks for the info!
you could also use a shorter sparkplug for some clearance under the tank ...i use the ngk br8ecm ... they´re exlusively made by ngk for the ktm sx 360 and sx 380.
... good job, will be a nice bike... 8-)
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09 kx450 used KYB forks.
those look just like the showas off my 250f
i would think they would be the same
[/quote]
They are different, I think you said you got a set of triples from a 450, if so they would have to be 450 forks, the Showa 250 forks are smaller at the triple clamp area. The shock does look more like a Showa than a kyb but a picture is hard to tell.
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yes the br8ecm plugs are 20mm shorter as br8eg . my fingers love the little bit more clearance between plug and my ´93 tank. :-D
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had to go look :-o at my reciept, yes in fact the forks are off a 2009 kx250f and the rear shock as well... I just had thought they where off a 450f
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hey, look on the bright side. now they are true to the sticker :-D
those are great forks though. thats the reason i went with the 09+, coated fork legs.
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HI, can you tell me which diameter of nozzle tungsten did you use for the different weld cords realized. thank you
SO WE MADE HUGE PROGRESS LAST NIGHT!! :beertime: (http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af2_zpsc2d1eeb1.jpg)
prepping the "Y" piece for welding
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af3_zps541a9b17.jpg)
fit like a d**n glove!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af6_zpsf6356f46.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af4_zpsa34da0c4.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af1_zpsc4c7feac.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af8_zps532a3559.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af12_zps09752024.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af11_zps56b1243a.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af10_zps4bddd2f8.jpg)
time to start bending tubing!!!!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af9_zps5e53c051.jpg)
The Rails and mounts fit perfectly!!!! :mrgreen:
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af13_zps8ca34e4c.jpg)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/kx500af14_zpsce355e9d.jpg)
tonight we weld it all together and start on the head stay! (Stay tuned!)
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not sure what size gas lens he used, but it was a 3/32 tugsten and he was using a water cooled setup
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[/quote]
I've just been assembling my engine and noticed that it has a Hinson clutch basket. So I started having a closer look at things. The primary drive gear is 16mm wide. The teeth on the basket are 12mm wide. Yet they only engaged about 11mm. Seems odd having such a strong primary drive gear and waste that strength by not using iT and also not permitting the clutch basket engage the full width of its teeth. Has anybody else noticed this?
[/quote]
ill check that out on my side when i go to assembly
[/quote]
Brooksie... mine is exactly the same way!?!?! im not sure why that is? i have not heard of any issues in regards to it? but yes mine is the same way
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Thanks for the update. Strange eh? I did think later that perhaps the power valve or water pump drive might make use of the extra width... But I can't think of a reason why either couldn't be inline with the clutch basket.
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more photos will be posted of current progress this afternoon
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SHE RIPS! :-o :mrgreen:
(http://i1358.photobucket.com/albums/q766/Clint_Lund/lundmx500af3_zps2a47dbe1.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/lundmx500af3_zps2a47dbe1.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/lundmx500af_zps46b90733.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/lundmx500af_zps46b90733.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/lundmx500af2_zps532fbf1e.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/lundmx500af2_zps532fbf1e.jpg.html)
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still have custom graphics kit coming. new triple clamps, seat cover, mudflap, hammer head rear brake lever and shift lever.
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Very nice.
that square silencer is awesome. who makes it?
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it was an old Answer muffler for a cr500
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http://www.ebay.com/itm/1990-Honda-CR-250-Answer-silencer-/300893081872?pt=Motorcycles_Parts_Accessories&hash=item460ea01110&vxp=mtr
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dang you knocked that thing out quick! nice job!
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ya! even my wife said "dam you finished already! :lol:" :roll:
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Great! Still working on mine. Did you have any problems with the rear brake pedal? Mine hits the clutch casing, so I'm going to have to do a little careful bending.
I just finsihed the adapter plate for the airbox this afternoon, really enjoyed doing it. Fits really well with no clearance issues on the shock.
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brooksie- every kx ive ever ownd the rear brake pedal rubs, if it worries you id just zip tie a peice of cloth to the brake pedal so it desnt scratch anything
lund- that is a sick build, ive been watching it in progress, wish i could ride that sucker! if you do any more builds post em up id love to see them
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brooksie- every kx ive ever ownd the rear brake pedal rubs, if it worries you id just zip tie a peice of cloth to the brake pedal so it desnt scratch anything
lund- that is a sick build, ive been watching it in progress, wish i could ride that sucker! if you do any more builds post em up id love to see them
It won't fit! lol
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Thanks Tkeen511! so far i love it. I will get some video of it soon as i finally heard word on the graphics kit and should have it in my hands in a day or so and then i will shoot a little video for the sponsors to have in there hands! Brooksie my rear brake lever; i ended up just using some spacers, its a little ghetto considering the fabrication and money that went into this build but the only other option would to be relocating the mount for the brake lever which im not sure of doing. also my front wheel hits the exhaust pipe "just barely but it does when bottoming" and i discovered at mid to top revving the bike has a miss and im not sure if it is electrical or carb... those are the wrinkles i am working on for this week
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Lund,
Have you ridden a CR500? I am building a CRF250-K5 AF and would like to know if the difference in motors is worth the effort? I will complete the bike but it would be nice to know I have something to look forward to. I have built a few Cr 500 AF bikes and love riding them.Thanks
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cmotodad: If you Check out Motocross action magazine for the month of May you will see FmF built a 2013 ktm 500 conversion. they did heavy testing on deciding which motor to use, they ended up using a kx500 engine because the power was more usable then Cr500 engine. check it out! http://motocrossactionmag.com/
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Thanks, I will check it out. Bob
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All right KXriders! she's 99.0% complete, just need the SH exhaust pipe. took her out yesterday for her 2nd round of testing and it performed awesome! im having problems with knocking and detonation so i am moving it to 1/2 race gas which should fix the problem..
But here is some final photo shoot pictures that was sent out to our sponsors! keep your eyes open for this bike as it will be racing the Pro vet nationals at glen Helen as well as the Monster Energy Mammoth Nationals! thanks so much to everyone on KXriders for your help and support, truely could have not done it without you guys!
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(http://i1358.photobucket.com/albums/q766/Clint_Lund/clints500af4_zpse0f97757.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/clints500af4_zpse0f97757.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/clints500af3_zps988f6dd8.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/clints500af3_zps988f6dd8.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/clints500af2_zpse178436f.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/clints500af2_zpse178436f.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/clints500af_zps696573b3.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/clints500af_zps696573b3.jpg.html)
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:-o d**n thats beautiful looking, idk if i could push myself to ride it when its that nice looking haha, cant wait for the vid
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*Update* 2nd round of testing is complete on the 500af. everything is going great so far. it runs a little hotter than i expected and im thinking racing gas is a needed step as this thing loves to knock and detonate! +Especially when hot!+ as far as my plug readings are telling me, the jetting is correct. *ALSO popping out of 4th gear only when just shifted into 4th; but if has been in 4th gear, it will not pop out. not sure yet if my boot is just tapping it out or if it's popping out due to shift fork problems.. love working out the bugs! any heads up on race gas i.e. mixture 50/50 with pump? straight?
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I mix 50/50 Rockett 100 with 91 Chevron. We're lucky here in Nevada as almost every Rebel gas station in Las Vegas sells it right at the pump. A select few Rebels sell 112 from the pump and there's I think two that sell even higher octanes. They're top octane boost can only be purchased in 5 gallon cans at select gas stations.
My 500 doesn't ping to bad on 91 but mostly when chopping the throttle quick and then twisting the throttle again right away. Just a couple of light pings. Not detrimental to the machine but annoying!
The 50/50 mix of Rockett 100 and Chevron cures the problem.
http://rockettbrand.com/
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I used to live in Pahrump NV. I miss the rebels hp gas at the pump!
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My sister still lives in Nipomo. I grew up in Cali, Paso Robles. Spent about 20 years in San Diego off and on when I was in the Navy and three years in Frisco. Decided to leave Cali in 1999 and haven't looked back. My family still lives there as most of them cannot afford to leave. Las Vegas is not the best place in the whole wide world to live but it's not so bad either! We often do the Cold Creek run from the state prisons all the way into Pahrump and slam a burger at the Sonic, refuel at Terrible's and head back over Mount Charleston to the ponds. Sheriffs don't care if you ride down the streets of Pahrump so long as you're not acting up.
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Dont remind me. Thats how i am, stuck here! Need an opertunity to snap me up out of this place. I loved pahrump! Just got too hot, "i hate heat"
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Bring your bike if you ever come over to visit!
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Plan to visit my parents soon. Maybe we can ride Pismo. I'll shoot you a PM in advance!
Later,
Pete
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My sister still lives in Nipomo. I grew up in Cali, Paso Robles. Spent about 20 years in San Diego off and on when I was in the Navy and three years in Frisco. Decided to leave Cali in 1999 and haven't looked back. My family still lives there as most of them cannot afford to leave. Las Vegas is not the best place in the whole wide world to live but it's not so bad either! We often do the Cold Creek run from the state prisons all the way into Pahrump and slam a burger at the Sonic, refuel at Terrible's and head back over Mount Charleston to the ponds. Sheriffs don't care if you ride down the streets of Pahrump so long as you're not acting up.
IF you come out this way.....Im in Lemoore may be we could all hit clear creek aka woods ranch the promise land.
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Sweet conversion!
Dont like the graphics/colors but thats personal..
Nice engineering! 8-)
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Thanks, i think lol :roll:
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Here is some up to date photos, added a new rear brake pedal, clutch and front brake asv levers, hammerhead shift lever, different grips. "Big things" added race gas (huge improvement! No more detonation) moved timing mark back to middle also (bled cooling system again, got more air out of it after tilting up front end :-D ... And also got the shorter ngk spark plug of which i will show pictures of the tank clearance: enjoy!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps3470130d.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps3470130d.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps9d5608df.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps9d5608df.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps60faeb3e.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps60faeb3e.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps9b021a3a.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps9b021a3a.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps31358e4f.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps31358e4f.jpg.html)
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Is your petcock valve touching the head?
If so, that is how I burned through my tank was trying to heat the tank plastic up and move it enough so that it wouldn't touch :cry:
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Hey Sandblaster, there's a much easier way to mould your tank. Boil it in water. I used the wifes' big kitchen pot on the stove. (When she was out!)
Kepp heating and moulding. The plastic will be very soft when it's hot, and doesn't take long to warm up. When you've got it how you want it, dunk it in a bucket of cold water and it will stay in shape. No need for a shorty spark plug!
Also, I cleaned the petcock casting up which gave me more clearance on the head.
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Yeah!
Thanks for that tip.
I was using a heat gun...
Did good the first 10 tries or so, then..... :roll:
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Here is another view, it does touch it ever so slightly, when sitting on the bike i can still slip a playing card between the two. Not sure if it is something i should worry about (http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps1b8fd1b4.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps1b8fd1b4.jpg.html)
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Maybe something like this over the air release on the head. Try it for a ride or two,, if it wears through it may be to close???
(http://www.betterbaseball.com/prodimg/HARC.jpg)
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That's another great idea..
Thanks!
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I picked up a couple vacumm caps today, ill try those, might need somethings stronger like a polymar or pvc... We will see
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Check it out!! here is some test ride video of it's third ride out! http://youtu.be/ZBOFM8UAm40
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Whoooohooo!
Looks like fun.
Nice job!
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We were just at Zaca on Sat. 1st time there, what a great track. As soon as I get the KXAFC sorted, we will be going there for a fun day. Nice bike.
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Here is another view, it does touch it ever so slightly, when sitting on the bike i can still slip a playing card between the two. Not sure if it is something i should worry about (http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps1b8fd1b4.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps1b8fd1b4.jpg.html)
Hey Lund,
You can solve this clearance issue by filing off those unused bosses and rounding the edges off on the petcock. It will give you 3mm at least. I did it to mine and it worked a treat.
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Re video. Could just be the quality of the video, but it sounds like the silencer needs repacking.
What gearing are you running?
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You should get a klx remote petcock set up, it is pretty flush under the tank and the petcock mounts on the frame, but you could put it wherever it works. It would keep from hitting the head.
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Hey alward.
Looks like the remote idea would work on my 07.
I'll play with the stock one tomorrow and then make a decision on how to do mine..
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Brooksie, yes im having issues with the exhaust system, muffler is freshly packed butdoes not correctly mate with exhaust pipe so it blows exhaust through the union. Still waiting on AJ @sh to get some pipes in stock then problem will be fixed. Good idea with the petcock, gonna try that!
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Brooksie, yes im having issues with the exhaust system, muffler is freshly packed butdoes not correctly mate with exhaust pipe so it blows exhaust through the union. Still waiting on AJ @sh to get some pipes in stock then problem will be fixed. Good idea with the petcock, gonna try that!
i made my modded cr500 pipe 10mm longer on the rear end for the correct pipe and muffler fitting and i use the stock cr500 exhaust seal between pipe and muffler... perfect and no problems. :-D
... you dont need a new pipe, you need a little bit work on yours, to eliminate this little problem... :mrgreen:
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I have been in touch with AJ wagoner from service honda, no dice on the pipes yet :? The converted cr500 pipe isn't working so well for me. At this point this is the only thing my bike needs to be perfect "in my eyes"
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just ran across this on ebay and vaguely remembered you looking for a pipe, not sure what the deal is with the AFC but figured it wouldn't hurt to post this http://www.ebay.com/itm/FMF-1-PIPE-KX500-GNARLY-88-02-270046-/171043050419?pt=Motorcycles_Parts_Accessories&hash=item27d2f5d3b3&vxp=mtr
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Lund,
Where are you located? I am having a pipe made from an old PC KX5 pipe and new cones from the headpipe on to fir the AF. It will be KX specs. I will let you know.
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Lund,
Where are you located? I am having a pipe made from an old PC KX5 pipe and new cones from the headpipe on to fir the AF. It will be KX specs. I will let you know.
I am in Orcutt, California PM me. stoked it needs a new pipe bad!
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ALMOST 4000 VIEWS! :bump: :-D ~~~ more updates to come soon! including new acerbis X-seat. v force 3 reed setup- airboot change- and final fab'd pipe!
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I'm all ears :lol:
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Hey well today I'm changing the reeds and I see this when I take out the reedblock this is after five hours of riding. Thoughts? (http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps4c58a0b9.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps4c58a0b9.jpg.html)
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Out with the old, in with the new technology (http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsdf2cf497.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zpsdf2cf497.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps05495bb1.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps05495bb1.jpg.html)
Daylight!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps44fdd150.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps44fdd150.jpg.html)
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Changing intake to 1999 kx250 intake because it does not have the wings that go into the reedblock and it looks like they are similar hight and angle
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps900b710a.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps900b710a.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zpsb681fc74.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zpsb681fc74.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps2c874cbc.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps2c874cbc.jpg.html)
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps7a6e56aa.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps7a6e56aa.jpg.html)
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More goodies to come!
(http://i1358.photobucket.com/albums/q766/Clint_Lund/image_zps7a6e56aa.jpg) (http://s1358.photobucket.com/user/Clint_Lund/media/image_zps7a6e56aa.jpg.html)
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(http://i1358.photobucket.com/albums/q766/Clint_Lund/th_IMG_1346_zps527bdbe9.jpg) (http://i1358.photobucket.com/albums/q766/Clint_Lund/IMG_1346_zps527bdbe9.mp4)
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LundMX - great build, and thanks for the detailed chronicle.
Can you post some pics of how you handled the radiator hoses in and out of the water pump? My PC pipe is pretty tight to the cylinder and I'm looking to see what you did. I bought a new set of 500 rads to modify.
I'm getting so close dude!