KX Riders
Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: hulkteam476 on March 21, 2013, 12:42:09 PM
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If is possible. Remember the year 2003, the Enduro of Touquet in France. kawasaki France had to create a KX500, even two.
Feb 10. 2003 - Nicolas Cailly performs the best start and finish the first lap in the lead(KX500Factory), thanks to a very great regularity, Yves Dedon(KX500Factory) completed the podium hundred percent tricolor, making this year his best result in six appearances.
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The chassi made by Kawasaki France was a steel frame KX250, 2004. With swing arm 250kx 2001, wider. 250kx radiator 2004 and Ohlins suspension.
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Hey!
Someone has my gas tank!!!! :lol:
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That headstay is sexy stuff
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It looks from the pictures that there only two bolts holding the upper head stay bracket to the frame. I believe this will not provide enough stability and you may end up with cracked or broken frame rails. The head stay mount cannot move or the frame rails end up handling to much of the load. Just going by your pictures.
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I vote to weld it 8-)
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Weld it! 10-4!
http://s155.photobucket.com/user/peteegger/media/KX500HeadStay001_zps6a0b0692.jpg.html
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It looks from the pictures that there only two bolts holding the upper head stay bracket to the frame. I believe this will not provide enough stability and you may end up with cracked or broken frame rails. The head stay mount cannot move or the frame rails end up handling to much of the load. Just going by your pictures.
Look harder. It has 4 bolts.. Plenty strong
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It looks from the pictures that there only two bolts holding the upper head stay bracket to the frame. I believe this will not provide enough stability and you may end up with cracked or broken frame rails. The head stay mount cannot move or the frame rails end up handling to much of the load. Just going by your pictures.
Look harder. It has 4 bolts.. Plenty strong
I only see two going to the frame? And one for the head stay. Not enough!
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It looks from the pictures that there only two bolts holding the upper head stay bracket to the frame. I believe this will not provide enough stability and you may end up with cracked or broken frame rails. The head stay mount cannot move or the frame rails end up handling to much of the load. Just going by your pictures.
Look harder. It has 4 bolts.. Plenty strong
I only see two going to the frame? And one for the head stay. Not enough!
Look harder.. there are 4 in the frame.
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It looks from the pictures that there only two bolts holding the upper head stay bracket to the frame. I believe this will not provide enough stability and you may end up with cracked or broken frame rails. The head stay mount cannot move or the frame rails end up handling to much of the load. Just going by your pictures.
Look harder. It has 4 bolts.. Plenty strong
I missed the 4 bolts originally.
I would probably weld it anyway but hey, there's a million ways to fix a Buick :-)
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the engine produces 74 hp carburetor is bored in 41mm (Oval not round).
It is the engine that made the holeshot touquet in 2003! and the first lap!!
Id love to see the dyno...
is this at the crank or the rear wheel?
and.. I wouldnt weld it in. too hard to work on.
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It looks from the pictures that there only two bolts holding the upper head stay bracket to the frame. I believe this will not provide enough stability and you may end up with cracked or broken frame rails. The head stay mount cannot move or the frame rails end up handling to much of the load. Just going by your pictures.
Look harder. It has 4 bolts.. Plenty strong
I missed the 4 bolts originally.
I would probably weld it anyway but hey, there's a million ways to fix a Buick :-)
Still don't know what you are seeing? I see the original 4 stroke mount bracket on the frame that has two bolts per side but I do not see where the fabricated head stay bracket has four mounting points to the frame? Maybe my PC is not loading all of the pictures for some reason?
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Ill color it in in paint for you.. gimmi one minn
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Ill color it in in paint for you.. gimmi one minn
(http://i13.photobucket.com/albums/a289/Motorrad/Kxmotor%202/IMG_1110_zpsea36d3bf.jpg)
(http://i13.photobucket.com/albums/a289/Motorrad/Kxmotor%202/IMG_1100_zps5d0d4f8a.jpg)
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Ill color it in in paint for you.. gimmi one minn
I see it now! Had to blow the picture up to see what I thought were drain holes that were threaded! I stand corrected. I would still weld it though for insurance.
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My only other suggestion would be to miter cut a spacer and run a through bolt like the front part of the bracket mount rather than relying on threaded aluminum if his design will not allow welding. Suspenders with belt with Velcro! Seen a lot of home made AF posts that weren't built strong enough and it's usually the frame rails that fail as a result.
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welding the head stay would make it hell to work on. could also be reasons unseen by us. perhaps you cannot take the motor out or in with these welded in place.
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The question is why in 2013, use a frame of 2002/04!????
Have you ever tried this agreement with the KX500 or CR500 engine?!??
I test others frames! (Always honda, 250, 450 cr / crf), this one is for me the best compromise between stability and agility. and then the swing arm is perfect and accept cavalry successfully.
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he had to find a good agreement between ground clearance and center of gravity!!
this is why the engine and the bottom of the tubes are so close. (Shakes, absorbed)
Remember that the chassis often used to make conversions cr500af is a 2005 CRF250, so! rear suspension, linkage and swingarm 250cr2007 after test, the agreement is better for the feedback info on traction with this 450crf02/04. The 3rd generation is also good 450 2006/2008.
for this frame, I used two examplaires
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this frame work wonderfully in supermoto with this triple clamp offset adjustable 14/16 20/22 23/24mm. This product is available through Paypal sent into the world with only ups for cr / crf / kxf. (details on request.)
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74hp... wow... what means this on rear wheel?
and i love these handmade headstay :-D
to find the right frame for the big 2 strokes conversions is a science in itself. and a aluminum frame is not as easy to weld like a steel frame. the steel frame you can weld directly next to the race track and then ride again. in the aluminum frame the heat distribution is even more important. it must rest a few days after welding before you can charge it fully. the fact helped me to decide on my steel frame.to get for my project a KX250F or 450f with broken engine would not have been difficult. we have mainly experience with steel frame. and the danger to me then something happens like in the picture I did not want to go. but i still love the kx 500af´s of service-kawasaki.but they´re way to expensive for my always low budget.. :-)
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The CDI unit mitsubishi kx 500
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74hp... wow... what means this on rear wheel?
and i love these handmade headstay :-D
to find the right frame for the big 2 strokes conversions is a science in itself. and a aluminum frame is not as easy to weld like a steel frame. the steel frame you can weld directly next to the race track and then ride again. in the aluminum frame the heat distribution is even more important. it must rest a few days after welding before you can charge it fully. the fact helped me to decide on my steel frame.to get for my project a KX250F or 450f with broken engine would not have been difficult. we have mainly experience with steel frame. and the danger to me then something happens like in the picture I did not want to go. but i still love the kx 500af´s of service-kawasaki.but they´re way to expensive for my always low budget.. :-)
I do not know if you saw the video of this england pilot? Here are the links to you tube.
Actually it is a risk, a bad weld or not closed! But the pilot had full confidence in the work! what style
http://www.youtube.com/watch?v=3TpKN3I6Y-Q (http://www.youtube.com/watch?v=3TpKN3I6Y-Q)
It's true that sometimes make a (withdrawal hot???)! (hot removal).
My friend Vincent R., imported the SH motorbike in France before, so we like it or not!(quality weld and process). We can recognize: Thanks to them! we can always ride with this two big hearts. CR500 & KX500 Engine
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74hp... wow... what means this on rear wheel?
Where is the Horsepower being measured from, The crank shaft, or the rear wheel?
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testimonies
on the original, understand by this: KX500 Frame CRF450
I'm working on two projects already mentioned by others.
The first: the redesign of the left central carter (Addition, cnc cut) to accommodate a hydraulic Brembo clutch. dot5.1
I put a picture if that person recognizes his bike? to take contact with me.
The second, a carter removable clutch. let me your experience with pics. Thanks
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great work ...this hydraulic clutch looks amazing. looks like what ktm build on theyr bikes.
i use a "hebo" universal hydraulic and the kx500 clutch is easy to pull like on a 85cc engine... 8-)
i found only the pics in the web of this broken honda. I'll watch the video ... to see what happened to him. motorcycle can be repaired. It is important that the rider is nothing bad happened. life is to short to get injured badly. :mrgreen:
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You're right, for my project this is the same as the ktm "Brembo"
master cylinder is also a Brembo racing!
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great idea to build it on the motor. but I saw a little problem. you cut off the bracket for the chain guide. times when the chain breaks it wants there to beat pure and destroy the hydraulic actuation ...
same problem can be on the ktm's when the chain guide was not installed. but you´re on a good way 8-)
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You will find a picture of the MONSTER that this Kawa fully completed will have to fight.
Now you can better understand the post "kx500 vs cr500 same frame different heart".
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yes! when david banner gets angry, he becomes GREEEEEN!!!!!!!!!!
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watch out boys... the hulk stomps through the street. and throws with tanks and helicopters on you .. :-D :-D :-D :-D
what kind of pipe you have installed on your green honda?
Now I've seen everything, green hondas, Suzukis in red, and I myself have blue gasgas plastics fit on my '97 KX250 ... the same would also be feasible with yellow or red plastics on my bike. :-)
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that bike looks awesome!
do you have any info on the brembo clutch retrofit with the slave cylinder on the side of the case?
i've got a "cable" pull brembo (drops in place of current clutch acuation) ready to put on mine but i've always wanted to do a real hydraulic setup like on the KTM's.
only thing that stopped me was the mechanical workings of them.
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that bike looks awesome!
do you have any info on the brembo clutch retrofit with the slave cylinder on the side of the case?
i've got a "cable" pull brembo (drops in place of current clutch acuation) ready to put on mine but i've always wanted to do a real hydraulic setup like on the KTM's.
only thing that stopped me was the mechanical workings of them.
crankcase kawa 500, seems pretty easy to change, since the original pusher is in the mechanical axis, in addition there is enough space in front of the pinion. of course
the crankcase can not have return back after modification.
The Brembo hydraulic tappet mounted on KTM's is ideal and does the same job as the original mechanical pusher kawa.
IMPORTANT this stuff, works at DOT5.1 and not Magura oil ....
Unlike the KTM 125 is seals for: oil Magura ...
If you're deceived oil, nothing works more ...
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Interesting to see this post on the hyd. clutch. I have a case that has been broken by a thrown chain. I talked with a friend that bleed KTM orange and asked him to use a slave cylinder to see it could fit. I now know it does. Thanks.
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Interesting to see this post on the hyd. clutch. I have a case that has been broken by a thrown chain. I talked with a friend that bleed KTM orange and asked him to use a slave cylinder to see it could fit. I now know it does. Thanks.
calculate the distance of penetration of the slave cylinder, compare this distance with the original KX500 (ref: 13102 RELEASE-COMP-CLUTCH) and you know or weld one piece CNC.
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I was going to machine the case to flat and weld a piece to the case to fit the slave. After reading the response, I will try to calculate the throw and use the stock rod too.
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I'm thinking machine the case flat, design a nice case saver/adapter, and making a longer rod. :|
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testimonies
on the original, understand by this: KX500 Frame CRF450
I'm working on two projects already mentioned by others.
The first: the redesign of the left central carter (Addition, cnc cut) to accommodate a hydraulic Brembo clutch. dot5.1
I put a picture if that person recognizes his bike? to take contact with me.
The second, a carter removable clutch. let me your experience with pics. Thanks
That is the bike of KawSF
"Yes this is a magura,from a 300 ktm.The case has been machined to accept the magura slave cylinder"
PM me if you cant get ahold of him. Ill dig out more contact info.
http://www.kxriders.com/forums/index.php/topic,5083.0.html
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testimonies
on the original, understand by this: KX500 Frame CRF450
I'm working on two projects already mentioned by others.
The first: the redesign of the left central carter (Addition, cnc cut) to accommodate a hydraulic Brembo clutch. dot5.1
I put a picture if that person recognizes his bike? to take contact with me.
The second, a carter removable clutch. let me your experience with pics. Thanks
That is the bike of KawSF
"Yes this is a magura,from a 300 ktm.The case has been machined to accept the magura slave cylinder"
PM me if you cant get ahold of him. Ill dig out more contact info.
http://www.kxriders.com/forums/index.php/topic,5083.0.html
Thank you, I already searched the forum, thinking they would not be alone ...
The post in question pictures to me are not visible (018.jpeg, 012.jpeg, lift and reservoir.jpeg, hydrolic clutch 500.jpeg)
Otherwise I'll contact him directly (KawaSF) Thanks (Motorrad)
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testimonies
on the original, understand by this: KX500 Frame CRF450
I'm working on two projects already mentioned by others.
The first: the redesign of the left central carter (Addition, cnc cut) to accommodate a hydraulic Brembo clutch. dot5.1
I put a picture if that person recognizes his bike? to take contact with me.
The second, a carter removable clutch. let me your experience with pics. Thanks
That is the bike of KawSF
"Yes this is a magura,from a 300 ktm.The case has been machined to accept the magura slave cylinder"
PM me if you cant get ahold of him. Ill dig out more contact info.
http://www.kxriders.com/forums/index.php/topic,5083.0.html
Thank you, I already searched the forum, thinking they would not be alone ...
The post in question pictures to me are not visible (018.jpeg, 012.jpeg, lift and reservoir.jpeg, hydrolic clutch 500.jpeg)
Otherwise I'll contact him directly (KawaSF) Thanks (Motorrad)
if He doesnt answer his PM's let me know. Ill try to get ahold of him via his registered email.
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important the air box ...
(coming soon) Completely made of aluminum
Great sound...
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the crf 450 2002/04 is very close plates at the numbers rear the cr 250 2003/07, which allows a better fit the (number) plate right at the muffler.
This does not work if you keep the original air box, it is possible than as adaptation If you construct the airbox completely.
Left side (number) plate CRF450 2002/04 original.
Right side (number) plate CR250 2003/2007 original
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few picts
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this frame work wonderfully in supermoto with this triple clamp offset adjustable 14/16 20/22 23/24mm. This product is available through Paypal sent into the world with only ups for cr / crf / kxf. (details on request.)
Hi,
where can I buy these triples?
I´m looking for crf ones.
Thanks.
Sorry that I didn´t start a own thread. Because I´m building an AFC with a KTM engine and a Hondaframe.
I´m reading here find a lot of superb ideas to build a bike.
Thanks guys.
If I find a good Kx500 engine I will build one :-)
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this frame work wonderfully in supermoto with this triple clamp offset adjustable 14/16 20/22 23/24mm. This product is available through Paypal sent into the world with only ups for cr / crf / kxf. (details on request.)
Hi,
where can I buy these triples?
I´m looking for crf ones.
Thanks.
Sorry that I didn´t start a own thread. Because I´m building an AFC with a KTM engine and a Hondaframe.
I´m reading here find a lot of superb ideas to build a bike.
Thanks guys.
If I find a good Kx500 engine I will build one :-)
hi broesel33 welcome to this site... which motor and which year of frame you use for the conversion?
i loved the powerful 380cc motor but i hated the pds-shock when i rode a buddies bike. this motor needs a good frame shocks and linkage around, to show his full potencial . you could start a thread in "my other bike" here on this site. i want to see pics. i love the green mashines, but i´m interested in all spezial build mx-bikes. :-)
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impossible to see the pictures that illustrated my post how to change this and make reappear images?? Motorrad??
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impossible to see the pictures that illustrated my post how to change this and make reappear images?? Motorrad??
you need now a photohoster like photobucket, picasa or so... it isn´t possible to post pics directly from pc since fall last year...
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really want to see these pictures back up!
hulkteam, im going to try and do a hydraulic clutch as well. mounted like the brembo on the side of the case.
one question i had was how do you determine its positioned straight in line with the pushrod. and also how do you find out the length to make the clutch actuator rod. i would think that the rod would need to be custom made because of the hydraulic version would be further out than the internal stock mechanical one?