KX Riders

Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: Danger4u2 on October 22, 2008, 03:30:18 PM

Title: Death/Rebirth of a KX500
Post by: Danger4u2 on October 22, 2008, 03:30:18 PM: I did it, I killed my 2001 KX 500. I yanked her heart right out of the frame. Her dead carcass was pushed to the back of the shop. Where her body will be picked apart by vultures wanting to keep their K5's on the trail (me).
The story continues .......................................
Title: Re: Death of a KX500
Post by: barryadam on October 22, 2008, 04:29:49 PM: But, why ...???? :-o
Title: Re: Death of a KX500
Post by: gwcrim on October 23, 2008, 12:45:44 AM: I CALL FIRST DIBS ON THE FRONT END, SHROUDS, AND REAR FENDER!!!!
Title: Re: Death of a KX500
Post by: gwcrim on October 23, 2008, 12:47:13 AM: Actually, I'd almost like the whole darn chassis.

??????????????????????????????????????????????
Title: Re: Death of a KX500
Post by: Danger4u2 on October 23, 2008, 01:45:17 AM: Sorry guys, I'll be the only vulture on this one.
Title: Re: Death of a KX500
Post by: hughes on October 23, 2008, 03:32:54 AM: Should have kept that one complete and torn down one of the other bikes. Must be a KX500AF in the works.
Title: Re: Death of a KX500
Post by: Danger4u2 on October 30, 2008, 03:02:43 PM: Quote from: hughes on October 23, 2008, 03:32:54 AM
Should have kept that one complete and torn down one of the other bikes. Must be a KX500AF in the works.

Yes, KX500AF, with the help of AJ of Service Honda, ahhh, Service Kawasaki.
http://www.servicehonda.com/kx500af.html
I searched Craigslist and E- Bay for more than 4 years looking for a near new KX500. I found the 2001 in St. Louis pictured earlier in this post. It was so nice I only rode it twice for 2 minutes, the day I bought it and the day before I removed the motor for the aluminum frame conversion AJ agreed to do for me. He gave me the choice, 2008 KX450F or the KLX450. The KX has a little more travel in the forks and shock over the KLX. The KLX has a battery and lights but not DOT. So I chose the KX and at a later date I can do a street conversion if I choose.
The E- Line coil will not work with the AF pipe that's required for the conversion.
http://www.elineaccessories.com/shop/Details.asp?ProdID=478&category=10&secondary=10&keywords=Lighting%20Coil
AJ hopes to develop a stator/coil set up for the Kawasaki similar to the CR500AF coil they developed. All builds are different depending the riders needs. He offers many options and aftermarket parts. Because of that prices will vary. If you have an interest in a KX500AF or for that matter a CR500AF give AJ an e- mail for quotes. ajwaggoner@servicehonda.com AJ shipped the bike in the original shipping crate the bike came in. Utilizing Yellow freight made the ship far less expensive than other shipping companies. I could not wait to receive it at the shop so I picked it up at Yellow's terminal early this morning. Some assembly is required, very simple. Handle bars, hand brake, front fender, number plate and the front wheel. The testing begins tomorrow...........
Title: Re: Death of a KX500
Post by: stewart on October 30, 2008, 03:06:17 PM: how does it ride
Title: Re: Death of a KX500
Post by: Danger4u2 on October 30, 2008, 03:11:46 PM: So far thumbs up. Feels flickable in the woods. My riding area behind the shop only allows 3rd gear, almost toped out before I have to slam on the brakes.
Title: Re: Death of a KX500
Post by: sintax on October 30, 2008, 04:32:30 PM: you know, i always seem to get the wrong mail delivered to my house, between the magazines and bills its non-stop.... How come nothing like that ever gets delivered by mistake!

Looks killer. Congrats!
Title: Re: Death of a KX500
Post by: Platypus on October 30, 2008, 05:28:25 PM: That is one nice looking bike you "had" there :-D . Correct me if I'm wrong but did'nt the 01 come stock with a green seat cover?
Title: Re: Death of a KX500
Post by: gowen on October 30, 2008, 11:07:58 PM: Oh my!!!! Did you get a discount for the engine?
Title: Re: Death of a KX500
Post by: maddoggy on October 30, 2008, 11:10:36 PM: whoa!!! santa claus came a little early for you this year. very nice bike Danger. MADDOGGY
Title: Re: Death of a KX500
Post by: hughes on October 31, 2008, 12:00:00 AM: Sweet bike.
Title: Re: Death of a KX500
Post by: Danger4u2 on October 31, 2008, 01:02:50 AM: Before I installed the fender I removed the 2001 fender to check fit. Keep in mind the KX500AF is a 2008 KX450F rolling chassis.
The fender does fit the 2001 K5, bolts right up. The number plate does not fit the contour of the 08 fender so if you use the 08 fender you would have to trim on the stock number plate. The number plates will not swap. Different type of mounts.
Title: Re: Death of a KX500
Post by: gwcrim on October 31, 2008, 01:21:18 AM: Is that a banana in my pants or do I love that bike????? :?
Title: Re: Death of a KX500
Post by: gowen on October 31, 2008, 03:00:08 AM: d**n, you make me want to walk out and buy a KXF450 (considering a new one anyway) and ride it till it blows then upgrade it to the KX500AF.. Daaaamn, that is sweet. Still curious if AJ gave you a deal for the engine tradein??
Title: Re: Death of a KX500
Post by: Danger4u2 on October 31, 2008, 03:23:15 AM: Yes, a substantial savings. Not something they do on a regular basis. The condition of the donor bike was part of the deal.
AJ is big on quality control, you can tell from the pictures. I had him leave the original graphics on the bike so I can jack with the heads of riders that "know everything". After a while I'll let them off the hook by telling them it's a Service Honda KX500AF built by AJ.
Title: Re: Death of a KX500
Post by: AJ on October 31, 2008, 04:23:40 AM: very cool bike! ;)
but then i'm obviously very biased .. ?? :)

I think once you get some serious seat time on it , you'll be in love with it..
Title: Re: Death of a KX500
Post by: alan on October 31, 2008, 04:48:59 AM: Danger you need to bring it down to El Paso and ride my Desert..................... :-D :-D :-D
Title: Re: Death of a KX500
Post by: Danger4u2 on October 31, 2008, 05:51:31 AM: When working out the details with AJ this was one of his quotes:

"For example I *will* build the bike as a rolling chassis, but yes the donor engines condition is very important to us, because the customers satisfaction in the final product relies so heavily on that,
and I need the engine physically here at my shop to drill the case halves properly for swingarm pivot bolt fitment."

As I said before all builds are different so e- mail AJ at ajwaggoner@servicehonda.com for more information.
Title: Re: Death of a KX500
Post by: sintax on October 31, 2008, 06:04:47 PM: Quote from: Danger4u2 on October 31, 2008, 05:51:31 AM
When working out the details with AJ this was one of his quotes:

"customers satisfaction in the final product"

"drill the case halves properly"

What planet is this "AJ" guy from...these are foreign concepts these days! I cant believe i'm hearing someone use these words
Title: Re: Death of a KX500
Post by: Uzi9mm on November 01, 2008, 02:21:17 AM: Thats the coolest bike ive seen in a long time...... 8-)
Title: Re: Death of a KX500
Post by: BigGreenMachine on November 01, 2008, 11:07:36 AM: Very nicely done AJ. Congrats Danger!
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 06, 2008, 04:53:51 PM: I bought a KX500 because they are bad a** and stand out in a crowd of same old, same old bikes. I bought a KX500AF because they are bad a** and they stand out in a crowd of KX500's if we ever get a crowd of K5's together. Now I need my AF to stand out in a crowd of KX500AF's. Some of this stuff is needed, some of it is wanted, some of it just looks cool.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 06, 2008, 05:03:12 PM: Quote from: Danger4u2 on November 06, 2008, 04:53:51 PM
I bought a KX500 because they are bad a** and stand out in a crowd of same old, same old bikes. I bought a KX500AF because they are bad a** and they stand out in a crowd of KX500's if we ever get a crowd of K5's together. Now I need my AF to stand out in a crowd of KX500AF's. Some of this stuff is needed, some of it is wanted, some of it just looks cool.
Title: Re: Death/Rebirth of a KX500
Post by: Uzi9mm on November 06, 2008, 06:56:57 PM: Dang Danger, did you hit the lotto?? That carbon fiber looks cool. Your AF is awesome. Its everything I dream of in a KX500...

:evil: 8-) :evil:
Title: Re: Death/Rebirth of a KX500
Post by: hughes on November 06, 2008, 11:59:51 PM: Very sweet. Please get you an offroad skid plate before you ride it. Portect those frame rails and engine cases. Again very sweet bike.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 07, 2008, 01:24:20 AM: Quote from: Uzi9mm on November 06, 2008, 06:56:57 PM
Dang Danger, did you hit the lotto?? That carbon fiber looks cool. Your AF is awesome. Its everything I dream of in a KX500... :evil: 8-) :evil:

No lotto but I do spend $4, 2 tickets a week with power play.
Same job, 17 years.
Job supplies a home here at the shop.
Paid off my home by 31 years old. Rented out.
Same girlfriend 15 years. Of the 5 long term girlfriends, first one that was not a dependant. 1st one that did not live with me.
No children of my own, her 2 kids and 2 grand kids are plenty.
Never been married.
I was debt free until 2004 when I messed up with the K5 and got hurt. My only debt now is from my crash. Got it down to $7000.
For therapy on my knee I would go to the casino every day in March of 07 not to gamble.
I would park way out in the parking lot and then use the stairs to go up to the pay window to enter for the truck I won.
Sold my 2005 truck $$.
I have never had a DUI or a divorce like most of my friends. Don't party like I used to. I keep out from behind the wheel.
If I use credit cards I pay them off each month. In the credit card industry I'm a dead beat.
The thing I give the most credit with helping me with my limited success:
From about 14 to 29 years old, if you didn't like to drink whiskey, chase women, and raise H***. I was NO fun to be around.
Now I concentrate on doing more good than the bad I have done. And I've got allot of maken' up to do. At almost 52 I'm running out of time.
If any of you younger guys would like some advice may I suggest http://www.google.com/webhp?sourceid=navclient&ie=UTF-8

Oh yea, never been married.

Post Script: The truck I won cost me 9 thousand dollars. State/Federal income tax, plus tag, title and state excise tax. I got a form 1099a for $32,500. This was not a gambling win.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 07, 2008, 02:10:00 AM: Quote from: hughes on November 06, 2008, 11:59:51 PM
Very sweet. Please get you an offroad skid plate before you ride it. Portect those frame rails and engine cases. Again very sweet bike.

You are so right!!! I was over looking that big time!!! Skid plates on all off road vehicles is a must!!! Now that you mentioned that I found many different manufacturers of skid plates for the KX450F on the net. Fitment becomes a problem because of the frame alterations and the pipe/pipe mount. Pipe runs real close to the frame on both sides. As soon as I make a decision on brand I'll do a how I made it fit. When I installed the Scotts shark fin I learned I could not remove the caliper from the caliper carrier without loosening the brake line. The line was not bent enough at the banjo head for the bolt to clear. Might be just my brake line. Any one else have this problem on their AF or KX450F? It sucked to have to breach the hydraulic system on a new bike. I think "brake fluid" is Latin for "gets all over everything and mess's up your paint". I was real careful, had plenty of paper towels and did a good wash up after completion.
Title: Re: Death/Rebirth of a KX500
Post by: stock500 on November 07, 2008, 06:40:42 AM: Holy hell I think a little bit of pee just came out!! That is my dream bike.
Title: Re: Death/Rebirth of a KX500
Post by: ID KX500 on November 09, 2008, 03:55:16 PM: Beautiful danger!

AJ,,, is it possible to get a KX500AFX,,, with Christini all wheel drive? :?

ID KX500
Title: Re: Death/Rebirth of a KX500
Post by: Panhead on November 10, 2008, 07:18:46 AM: Now that is a machine! WOW! You did good there. I'm in awe every time I ride my stock K5 with pipe. You guys here are serious power junkies. :evil:

Heres to keepin' it on the pipe! :-D
Title: Re: Death/Rebirth of a KX500
Post by: AJ on November 10, 2008, 08:52:12 AM: ID-

I've spoken with Christini a few times about a project bike, as we are both interested in doing one together, but time /schedules etc havnt panned out yet.

as far as a customer ordering a KX500AF with all wheel drive..
i'm sure they could build it..!! they do some amazing work.
i would simply supply the bike to christini and they would take it from there.

:)
Title: Re: Death/Rebirth of a KX500
Post by: ID KX500 on November 10, 2008, 10:20:16 AM: I have talked to them several months ago about using the new KX frame, they indicated that they were sticking with the Hondas and KTMs for the time. I don't know why the KX frame is not doable but if that is the case, is it possible in your experience to drop a KX500 motor into the Honda CRFX frame? Also what is the deal with your project on the other thread. Looks like an exhaust valved 2-stroke,,,,,,what size bore?
Title: Re: Death/Rebirth of a KX500
Post by: AJ on November 10, 2008, 11:03:08 AM: hmm, on the christini ,, i'd have to talk to them about the KXF frames ,as theyt are quite similar to a CRF.
but yes when we spoke before , it was in regards to a CR500AF
(CRF framed)

on the other thread,
it's a new KX250F chassis, and a new (stock) KX250 engine.
-just putting it in the new chassis since Kawasaki isn't offering the bike
:)
Title: Re: Death/Rebirth of a KX500
Post by: maddoggy on November 10, 2008, 11:42:46 AM: the christini setup looks very good, however, if they are unwilling to try a kx500 or any other non standard bike maybe that is why they are stuck in the position they are in marketwise. if i were building something like that i would be willing to try ANY bike.

on another note, AJ, have you ever considered having an aluminum frame covered/coated in carbon fiber? that would look pretty killer, although would very likely be expensive. MADDOGGY
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 11, 2008, 04:50:28 PM: I installed a set of Works Connection radiator braces. They have you cut off the plastic tab on the white plastic louver that sticks through the upper hole in the radiator. I used a grinder and did not grind it all off. I left about 1/16 that way you can easily find the center to drill the 1/4 inch hole plus it will center itself in the hole of the radiator. I think AJ relocates the coil and I had to grind on the left brace to make it fit. Where the new bolt go's through the louver they have you cut out some of the bracing of the louver. I used an x-acto knife and only cut out enough to fit the washer instead of removing all of it. Cut out that part of the bracing before you drill or it will make the drill bit wander. In stock form the radiator shroud is the only bracing of the radiator. Works Connection makes a radiator cage also but you can only use the cage or the brace. I chose the brace because it supplies bracing on the front to back movement of the radiator. The cage would give it bracing on a side impact. Install time was a half hour.
Fit and function I give a 10, price I give a 6.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 15, 2008, 08:22:00 AM: Getting close to finishing the aftermarket bolt on's.
Got to hand it to Scott, everything exact fit, very easy install.
Fit and function 10
Price 8
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 17, 2008, 05:29:39 AM: Took the K5AF out to do a real test ride. What a difference over the stock K5. It was late when I arrived at Crosstimbers riding area. With the Scott under mount steering damper and the Pro Taper Kevin Windham bend bars, I've raised the grips about 2 inches.
This makes it great when standing in the rough stuff. The K5AF seems to get better grip and less wheel spin out of the corners. With the sun low when I got there I stuck to the 12 mile loop shared with quads. I did not want any handle bar issues in the long shadows. There are 2 areas on the motorcycle only track that I have to stop to get bars through some close trees. I need to give it a good clean up, check all the bolts and adjust the chain. With the donor motor I don't have a break in period. I am giving the chassis about 4 hours before I do any adjustment.
Title: Re: Death/Rebirth of a KX500
Post by: gowen on November 17, 2008, 05:49:38 AM: David, after seeing how clean it was, that mud makes me sad. It just hurts to see something that beautiful so dirty.. HA-HA
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 17, 2008, 06:13:46 AM: I know what you mean. I went around the first few then I hit the big monster hole. Covers the whole trail tree to tree. After that I just did a wheelie across the rest.
Title: Re: Death/Rebirth of a KX500
Post by: jfabmotorsports.com on November 17, 2008, 07:56:08 AM: Danger, who made your carbon pipe cover? JFAB
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on November 17, 2008, 08:42:20 AM: I ordered it with the bike. E- Line makes it for AJ's pipes. I bought one for my 2004 K5 to fit my FMF Gnarly. The other carbon fiber items I purchased from Light Speed.

http://www.elineaccessories.com/

http://www.lightspeedperf.com/
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on March 27, 2009, 04:37:39 PM: OK AJ. My bike carries it's real name now.
Title: Re: Death/Rebirth of a KX500
Post by: AJ on March 30, 2009, 02:22:12 AM: nice!! :)

what prompted you putting them on?
tired of running *stealth* mode? :)
heh
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on March 30, 2009, 02:32:15 AM: Yes, got tired of answering all the questions "When did they start making a 450 2 stroke?"
Stock Kawasaki graphics are so expensive, I felt it was cheaper to get new number plates. I can always sell the 450 plates.
I hate to waste anything, gas, electricity, water, or KX graphics.
Title: Re: Death/Rebirth of a KX500
Post by: franciskx on September 12, 2009, 11:15:28 PM: Muy bonita la moto, felicidades tio....??esta moto se puede comprar para espa?a?
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on September 13, 2009, 08:30:27 AM: No, it's made in the U.S.A. by
Service Honda.
http://www.servicehonda.com/index.html

No, est? hecho en el U.S.A. por
Servicio de Honda.
http://www.servicehonda.com/index.html
Title: Re: Death/Rebirth of a KX500
Post by: azracer19 on September 17, 2009, 06:16:41 AM: just wondering will a desert tank fit on that bike?
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on September 17, 2009, 07:25:13 AM: I bought an IMS tank, started to make it fit but needed help. It hits the spark plug, the coil (relocated because of the 500 motor) and the radiator braces I installed. Bought a heat gun but need someone to throw cold water on the areas I was trying to heat while I held the spot in place. No one was around the day I was working on the tank, so I put the bike back together so I could ride. It kind of turned into winter job. Stock is 1.9 gal. IMS is 3.2 gal. The way you have to melt and push in the tank to fit, I think you lose a little. Adding the IMS tank will add about an extra gallon.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on September 17, 2009, 10:08:59 AM: In the last picture you see the contact with the coil and brace.
Title: Re: Death/Rebirth of a KX500
Post by: tharden on September 27, 2009, 09:23:40 AM: All I can say is NICE. Just think of what the kx500 engine internals would be like now if they upgraded it like the 250.
Title: Death/Rebirth of a KX500
Post by: Danger4u2 on November 17, 2009, 07:01:55 AM: With more and more woods/tight trail riding I'm doing now, I thought it was time to up grade the K5AF. It's no fun to bash you fingers on the trees. So before I do that...........Here's the upgrade.

First I need to give Jerry at http://jfabmotorsports.com/ a thank you for suggesting I use a Honda front brake master cylinder.
It gives the KX500AF the clean look it needed for the installation of the Cycra Probend CRM hand guards 1-1/8"bars (CRM-Center Reach Mount). http://store.cycraracing.com/ceremo11ba.html

I ordered a 2008 Honda CRF450 master cylinder, if you do this don't forget to order the plunger that goes between the handle and hydraulic cylinder. It's not part of the assembly. http://www.servicehonda.com/parts.html
The problem with the KX master cylinder I encountered was the location of the banjo bolt on the hydraulic brake hose. It comes off the front of the cylinder right into the Cycra mount. The Honda master cylinder has the banjo coming off the back side of the cylinder. And it should clear the mount. Jerry told me this and he was correct. Problem solved. Did not have to bend the hand guard mounts.

I'm also a big fan of AVS clutch and brake levers.
http://www.asvinventions.com/levers_order/C5_Series_Levers/CLM03_off_road_c5.html
I installed the C/5 Series Pro Model Clutch/Perch and the C/5 front brake lever. I bought the "Shorty" version to avoid any fitment issues. You don't have to cut the end off the lever to fit with the hand guards or move the perch in, on the handle bar. I like how they are adjustable for big or small hands.
I called ASV to talk about using ASV Honda parts on a Kawasaki and Karen fixed me up with all the correct part numbers. She also told me if I buy from ASV it would be list price. One of those "Can't undercut my retailers". She suggested one of her retailers that discounts her products.
http://www.rcalracing.com/index.html
That saved me a few bucks. ASV levers are very popular, they run back orders 3 to 4 weeks behind.
Every time they run a batch of levers Rick at R-CAL Racing is the first order filled, he's just across the street from ASV.
Give him a call and he will get them to you as fast as he can.

Everyone that help with this upgade was easy to get along with and very helpful.
Thanks, Jerry, Karen, Rick, Cycra, and the parts guy at Service Honda.
Title: Re: Death/Rebirth of a KX500
Post by: cr37 on November 19, 2009, 06:03:14 AM: The honda brakes work alot better than the stock KX brakes, I replace the whole system with a Honda and love it stops alote better.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on August 16, 2010, 05:54:03 AM: I ordered a set of Vibranators. Handlebar vibration eliminators.
The concept sounds like it will work.
I'll do a follow up after I do a full before and after test.

http://www.vibranator.com/default.asp
Title: Re: Death/Rebirth of a KX500
Post by: jbersano on August 17, 2010, 02:59:38 AM: this is love.... :mrgreen:
Title: Re: Death/Rebirth of a KX500
Post by: 2-Stroke Tom on August 17, 2010, 08:43:11 AM: I have the virbranators on my KX500, and they made a noticeable improvement. Vibranators and 4 Honda OEM handlbar mount bushings (BRP racing sells Honda OEM bushings, so I gave them a try) and my virbration problem is cured.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on August 17, 2010, 04:08:40 PM: This Thursday I'll have the final tig welding done to the Pro Moto Billet back rack. Had to do allot of fabrication to make it fit the AF bike. It's made for the KLX450F. I think it looks good. Sure don't want to loop it out. Hope to fire it off and ride this weekend. Here's where I'm at so far. Click on the first picture, it's a video.

(http://i126.photobucket.com/albums/p102/DrtBik/th_2008KX500AFreassemblypart2.jpg) (http://s126.photobucket.com/albums/p102/DrtBik/?action=view&current=2008KX500AFreassemblypart2.mp4)
Title: Re: Death/Rebirth of a KX500
Post by: ID KX500 on August 18, 2010, 01:28:34 AM: Hey Danger, I'd be very interested in more details of how you mounted your rack. I put one on my 450F but removed it after hauling extra gas, it got quite loose on my left side, my mounting was a little cheesy, my right hand side was OK. I talked with a guy from Promoto Billet about making one for the KX, I think I'll email him this thread maybe they will design one for the KX.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on August 18, 2010, 04:36:28 AM: When I called Pro Moto (PM) I asked if anyone had tried to mount it on a KX450F. They are made for the KLX450R. The salesman said he has a KX and it took a little cutting but he made it work. I have not finished with the install yet. The spacers that came with the unit are the wrong fit on the MX bike. I driller them out to fit the seat bolt. I drilled out the threads on 2 small nuts for spacing the lower mounts. The muffler Service Honda (SH) uses is not compatible with the rack. They use the seat bolt as the top mount for the muffler. I had a new mount machined and tig welded and it utilizes the stock mount hole. I cut off the SH mount. It left a scab that I dress up the best I could. It's covered by the number plate. The muffler sticks up and back more than the stock muffler. I had my machine shop guy cut the right side mount to fit with the muffler. This took away from the strength it had so he machined a part to fit between the mounting points to add strength. I will have to cut the number plate to accept the reworked mount. I'll get some pictures and add them to this post after work so you will have a better understanding of what has to be done.
Title: Re: Death/Rebirth of a KX500
Post by: ID KX500 on August 18, 2010, 05:11:09 AM: Thread in KX450F/KX250F section of mounting a ProMoto Billet Rack on a 450F

http://www.kxriders.com/forums/index.php/topic,7911.msg60753/topicseen.html#new

Thanks Danger, sounds like you have a different problem on your right side. I'll post my fix also when I get a round tuit, I've been trying to get my riding in this summer before the snow flies again. A pic of what it looked like before it got loose. It was nice to be able to have an extra 2 1/2 gal.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on August 18, 2010, 08:47:28 AM: When I had the bike torn down I took the airbox out of the sub frame and noticed the pipe was melting it. I wanted to put header wrap on the hot area but the hot rod shops only had it in 50ft. rolls at $2.25 a foot.
I found a 16ft. roll at NAPA Auto Parts for $20 bucks.
So now I have 14ft. of header wrap I will never use.
I put it on with stainless tie wire and hose clamps.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on August 24, 2010, 01:33:50 PM: I would like to thank gianni2takt for showing us where to drill the head and how to install the compression release. I would like to thank Larry for doing the work on the head. And the biggest THANKS to Stewart for going through my motor, making it the best it can be.
A thank you goes out to Factory Connection Muskogee Oklahoma location for the respring and revalve of my forks/shock. So far I have only done my first start up/warm up so I have not done the "real" riding/testing yet. I'll do a follow up post on how it all works together after I go through the break in process.
Title: Re: Death/Rebirth of a KX500
Post by: DoldGuy on August 24, 2010, 03:24:29 PM: Danger,
I'm sure if your knees could speak (or type) they would also be thanking Larry! Did it make it alot less painful kicking for you? I can't hardly kick mine over without the release.
DoldGuy.
Title: Re: Death/Rebirth of a KX500
Post by: Danger4u2 on August 24, 2010, 04:24:07 PM: I feel kind of stupid. Like I was a school boy at his first dance. I've had this thing apart since mid February. I gassed it up with 32 to 1.
I run 40 to 1 after break in. I filled the radiator with 50/50 distilled vinegar and distilled water to flush the system. Got a cinder block to stand on for more leverage. Gave it 2 slow prime kicks. Compression release working great! Then I gave it 5 mule kicks and nothing.
Forgot to turn the gas on. 53 years old and still a newbie. 2 slow prime kicks. 2 more mule kicks. Forgot to choke. With the choke and the gas on it fired in 1 kick and ran perfect. I ran it for 7 minutes putting around the parking lot, killed it and drained the radiators. I have a grass hill in the back at about a 45 degree angle, lay the bike over for a second you get all the water out. Forgot to turn OFF the gas (newbie). Refilled with straight distilled water and set up the shop fan to cool it off faster. A few hours later I did a 10 minute putt around/drain refill. In the morning I'll do another 10 minute putt around, drain and refill with engine ice. After that I'll ride it fairly easy until I need to gas up. After that I'll ride it like I stole it. Yes the compression release made it almost painless. The AF bike is not easy to kick because the kicker on the 2 stroke does not stick out as far as the 4 stroke motor. If you don't have your foot just right your heal hits the number plate.
Man time fly's, Good night.