KX Riders
Maintenance & Technical => KX500 Steel Frame Conversion (SFC) => Topic started by: El Snorro on February 11, 2014, 12:14:02 AM
-
I am building a kx500 '85 engine in a kx250 2001 frame.
The engine is fitted, but the air hose going to the airbox is way too low... How have other kx500SF builders solved this?
(engine will be a bit more leaning forward if final engine mounts are welded to the frame)
thanks
(http://i166.photobucket.com/albums/u82/ElSnorro/Screenshot_2013-12-23-22-37-57-1-1_zps34cc6d45.jpg) (http://s166.photobucket.com/user/ElSnorro/media/Screenshot_2013-12-23-22-37-57-1-1_zps34cc6d45.jpg.html)
-
It looks as though the motor has to drop quite a bit, the center line of the countershaft, the center line of the swingarm pivot and the rear axle at half the travel need to be aligned otherwise you have chain tension issues.I've built a few 500/250's like yours and always used the stock 99-02 250 airboot. I would not go with a uni type filter and a hose to the back of the carb, I know of people that have tried it and it did not work right. I have never used a 85 motor, but have used 86-88 version and the 89-04 versions, can't imagine the 85 is that much different on bottom case placement.
-
The above pic was old setup with motor mounts of 250 frame still being in place.
This is how the engine is now:
(http://i166.photobucket.com/albums/u82/ElSnorro/IMG-20140211-WA0040_zps2wwwqwj7.jpg) (http://s166.photobucket.com/user/ElSnorro/media/IMG-20140211-WA0040_zps2wwwqwj7.jpg.html)
When i mount the carb the float bowl is touching the engine casings.
-
The above pic was old setup with motor mounts of 250 frame still being in place.
This is how the engine is now:
(http://i166.photobucket.com/albums/u82/ElSnorro/IMG-20140211-WA0040_zps2wwwqwj7.jpg) (http://s166.photobucket.com/user/ElSnorro/media/IMG-20140211-WA0040_zps2wwwqwj7.jpg.html)
When i mount the carb the float bowl is touching the engine casings.
http://der-motopunk.de.tl/projekt-kx500-.htm
here you can find my solution with 86 kx500 engine in ´93 250 frame.. the watercooled engines 85 to 2004 are more similar as it looks in first sight...major diference are the cylinders between the years
... i made a spline that lowered the manifold with the carb and the stock airboot is flexible enough that it works. you are in the position, that you must make an adapter to fit the later kx500 manifold to the 85 engine with its only 4 mount-holes for reedcage and manifold. later versions(86-2004) have 6 holes... you should also look for enough clearance to the shock for the carb boot, if all is installed..
which carb do you use? the roundslide-mikuni of the 85 engine or an pwk ?
-
The above pic was old setup with motor mounts of 250 frame still being in place.
This is how the engine is now:
(http://i166.photobucket.com/albums/u82/ElSnorro/IMG-20140211-WA0040_zps2wwwqwj7.jpg) (http://s166.photobucket.com/user/ElSnorro/media/IMG-20140211-WA0040_zps2wwwqwj7.jpg.html)
When i mount the carb the float bowl is touching the engine casings.
http://der-motopunk.de.tl/projekt-kx500-.htm
here you can find my solution with 86 kx500 engine in ´93 250 frame.. the watercooled engines 85 to 2004 are more similar as it looks in first sight...major diference are the cylinders between the years
... i made a spline that lowered the manifold with the carb and the stock airboot is flexible enough that it works. you are in the position, that you must make an adapter to fit the later kx500 manifold to the 85 engine with its only 4 mount-holes for reedcage and manifold. later versions(86-2004) have 6 holes... you should also look for enough clearance to the shock for the carb boot, if all is installed..
which carb do you use? the roundslide-mikuni of the 85 engine or an pwk ?
Thanks for your reply. Will try
I want to use a PJ38mm from a honda CR250 which i had 'on stock'
Do you have more detailed 'high resolution' pics of the spline&boot? thank you very much
-
i will later try to post them in bigger size as on my website ... somewhere on pc i have pics of a friends bike , that he bought last year. its a 96 kx250 with 85 kx500 engine. i think that will also help you.
the 38 pj-carb is worth a try. i use the 39 pwk .
-
here are pics of the 85 engine in the 96 kx250 frame ... yo´ll see that the spline works as adapter . bolted to cylinder with 4 bolts and the manifold is bolted only to the spline (dimensions are 15 to 5 mm)
(http://i939.photobucket.com/albums/ad234/michik23677/CIMG2087_zpse49b022e.jpg)
(http://i939.photobucket.com/albums/ad234/michik23677/CIMG2088_zpsc506c0e3.jpg)
here is my 86 engine again. the spline that i made is 10mm to 1.5mm ..
(http://i939.photobucket.com/albums/ad234/michik23677/Foto0318_zps37d69dfa.jpg)
(http://i939.photobucket.com/albums/ad234/michik23677/Foto0316_zps25f43aaf.jpg)
(http://i939.photobucket.com/albums/ad234/michik23677/Foto0317_zpse9ac22a7.jpg)
and the first sit in of the engine in my 93-frame... you see the height-diference of manifold without spline and carb boot ...
(http://img.webme.com/pic/d/der-motopunk/foto-0029a.jpg)
-
Thanks :)
-
Thanks :)
no problem... :-) are you from netherlands? saw the internet-adress on your bike..
-
Yes I am from NL :)
-
Yes I am from NL :)
ok, i send you some greetings over the border from germany... :-)
-
It's a small world :-D
Last week I crossed that border to Kaarssen, Amt Neuhaus :mrgreen:
Dutchie
-
It's a small world :-D
Last week I crossed that border to Kaarssen, Amt Neuhaus :mrgreen:
Dutchie
the world is a little village .. :-D i live on the other side, close to poland... stettin(szecin) is only 65km from me...
-
I looked at www.der-motopunk.de.tl (http://www.der-motopunk.de.tl) to see were your from to find some tracks.
I used http://www.mxbrothers.com/mx-tracks/germany to find some.
A client from us has his farm here https://maps.google.nl/maps?q=laaverstrasse&ie=UTF-8&ei=2lUGU5HwCuvs0gWSxIGgDQ&ved=0CAcQ_AUoAQ (https://maps.google.nl/maps?q=laaverstrasse&ie=UTF-8&ei=2lUGU5HwCuvs0gWSxIGgDQ&ved=0CAcQ_AUoAQ). Me and my colleague talk about to take the bikes with us to ride in the Woods.
Compared to the US, your close by and El Snorro is a neighbour.
Dutchie
-
"Compared to the US, your close by and El Snorro is a neighbour."
but its still one day in the car .. :-D i have 10 mx-tracks around where i can get in less than 1 hour ..
here is a event,that we do at the mx-gp-track in schwedt / oder
(http://i939.photobucket.com/albums/ad234/michik23677/flyerclassictreffen-schwedt2014_zps7ebcab1c.jpg)
would be cool if you provide it a little bit in nl , and some nl-classic guys would come also.. 8-)
at the track in schwedt is in may also a race to the sidecar-world-championchip
-
I do ride classic mx (pre90) on a honda CR250 1989
We have about 15 races each year on various tracks in nl. For more info please visit www.vmcn.mx
My honda:
(http://i166.photobucket.com/albums/u82/ElSnorro/DSC_8158_zps1235ad8d.jpg) (http://s166.photobucket.com/user/ElSnorro/media/DSC_8158_zps1235ad8d.jpg.html)
-
i´m not the biggest honda-fan on earth, but your bike looks hot, like new 8-)... is the wp-fork better than the showa usd fork?
the evo-class pre90 comes this year new to the dmv-classic-cup . last year for the first time in european championchip.
http://www.dmv-motorsport.de/index.php/motorsport/motorradsport/meisterschaften/145-dmv-classic-motocross-cup-links-pruefen
www.classicmx.se
-
Yes the wp forks a fully adjustable and much better than the original showa forks.
They rode GP's back in the days with thos WP units.
I also have KXF250 2012, but I am having twice as much fun on the old bikes!
What tracks on that list are a bit close to the NL border? I am interested in riding a race or 2 if not too far away, and i think my fellow NL racers do like it also.
-
Yes the wp forks a fully adjustable and much better than the original showa forks.
They rode GP's back in the days with thos WP units.
I also have KXF250 2012, but I am having twice as much fun on the old bikes!
What tracks on that list are a bit close to the NL border? I am interested in riding a race or 2 if not too far away, and i think my fellow NL racers do like it also.
from this list is schnaitheim the closest track to nl .. 2 in northeast and and the rest is in south . i plan to ride in barth and eberswalde and our local championchip here in northeast.
-
That is still 6 hours driving :P :P
Too far, sorry
-
That is still 6 hours driving :P :P
Too far, sorry
from me 8-9 hours .. and i have no mobilehome and to less money at the moment to plan trips like that... most of the tracks are 6-7 hours away from me... :|
like joel smets said a few years ago in an german interview: "germany must be bigger than belgium and netherlands together!"... :-D
-
Hi El Snorro! What's up with the conversion project? We want to see some progress!
-
Took a while :P
But the 500SF is on its wheels and running, just need to test it on the track :)
(http://i166.photobucket.com/albums/u82/ElSnorro/IMG_20150530_170142_zpsyocbikdp.jpg) (http://s166.photobucket.com/user/ElSnorro/media/IMG_20150530_170142_zpsyocbikdp.jpg.html)
(http://i166.photobucket.com/albums/u82/ElSnorro/IMG_20150530_165935_zpsboyuhin0.jpg) (http://s166.photobucket.com/user/ElSnorro/media/IMG_20150530_165935_zpsboyuhin0.jpg.html)
-
Looks great! I can't wait to hear your ride report. Did you run into any other issues after fixing the air boot?
-
Umberto,I used the stock 500 airboot and filter cage/seat. I made an adaptor plate and bolted it to the 04 250 airbox. The 03 airbox is slightly different but should work fine.
-
the guy who build it for me had to do quite a bit of work actually. Cut the swingarm+bushes to acces the engine.
And create a custom intake adapter
(http://i166.photobucket.com/albums/u82/ElSnorro/IMG-20140812-WA0017_zpsczi8qigq.jpg) (http://s166.photobucket.com/user/ElSnorro/media/IMG-20140812-WA0017_zpsczi8qigq.jpg.html)
(http://i166.photobucket.com/albums/u82/ElSnorro/IMG-20140812-WA0016_zpshq9k4bat.jpg) (http://s166.photobucket.com/user/ElSnorro/media/IMG-20140812-WA0016_zpshq9k4bat.jpg.html)
(http://i166.photobucket.com/albums/u82/ElSnorro/IMG-20140812-WA0015_zps49sbwkmn.jpg) (http://s166.photobucket.com/user/ElSnorro/media/IMG-20140812-WA0015_zps49sbwkmn.jpg.html)
And the exhaust+silincer had to be cut and welded to fit (cr500 exhaust)
And use this spark plug/cap to fit the tank
(http://i166.photobucket.com/albums/u82/ElSnorro/crf250r002_zpsrggrxklz.jpg) (http://s166.photobucket.com/user/ElSnorro/media/crf250r002_zpsrggrxklz.jpg.html)
-
what plug number is that on the left??
-
PM El Snorro as I suggested.
-
PM El Snorro as I suggested.
Already did..
-
I am going to guess that is a BR8ECM. It's shorter than a regular plug. I run an ECM in my 03 steel frame conversion after reading one of the other steel frame conversion threads. There is also a BR9ECM if you need that heat range.
The plug cap is made by NGK, and is a resister plug cap. I found one here: http://www.ngk.com/product.aspx?zpid=20169 (http://www.ngk.com/product.aspx?zpid=20169). The part number is TRS-1225