KX Riders
Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: kneedrager428 on April 21, 2009, 12:11:51 PM
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So I am thinking of using a 99 cr250 for my kx500af project. Is there any info on this swap? I have searched and came up with nothing. I have the engine in the frame and surprisingly the swingarm bolt and the lower engine mount line right up. The front mount is only like 1/2 inch off. So it seems like the mounting will be the easy part.
Does anybody know if the cr500af pipe would come close to fitting my application?
I have put some pics here:
http://office.flyelite.com/dan/KX500%20CR250 (http://office.flyelite.com/dan/KX500%20CR250)
Let me know what you think and any info on pipes would be much appreciated. Thanks, Dan
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Hows the spacing for the spark plug and the top engine mounting?
Looks very do-able. This seems to be much less hassles than using KX alu frames.
Ta 4 sharing and please post progress!
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It looks like a regular plug will work. With the tank on it looks OK. I will try a plug in it to be sure but I am still wondering about a pipe solution. There are not many fab shops around here and None that i know of that have 2 stroke experience.
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Also There will be no progress if I cant figure out a pipe. I will finish my original 500 restoration. I will not get rid of my 500 rolling chassis if I finish this as I like to have the option of having a mint 500 if I wanted.
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The pipe is easy. Finish the bike and send it to me. You get a fat pipe and a skinny wallet! :-D
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Your work looks trick but shipping the bike that far is not a $$ option I have right now. :-(
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the closest "off the shelf" pipe and silencer
would be the one we have for our KX500AFs'
www.servicehonda.com
i certainly cant gurantee fitment..
but it should get you i nth eball park..
the rear mount on the stinger would need to be relocated ..
but the general bend and low boy style KX500 pipe would be in the right spots for the most part and *should* fit the bike well,
at least much closer than anything else besides a one off pipe made specifically for the bike..
(which of course in this hybrid case is the best option )
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I think AJ's pipe would be your best bet. The only issue I ran into with fitting it to my KX steelie was right at the water jacket coming out of the cylinder. Here is a pic of my fix for that.
(http://c3.ac-images.myspacecdn.com/images02/104/l_d91b8a7596ff4bb1891083330bc39f42.jpg)
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This is going to be an awesome project. You get the handling of the CR, with the awesome and unsurpassable power of the KX. Very cool indeed :evil:.
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If the Service Honda pipe fits as well as it did on my conversion, you're going to be one happy camper! All I needed was to have some frame mounts fabricated. It's not a huge issue to clear the water hose. I used 3/4" copper elbows to loop around in a similar fashion to the Service Honda hose.
Great idea you have there!
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The only thing I didn't like about the '99 CR250 I had was that hard, monkey butt making, seat. (and the 500 power!) I rode my buddy's '02 the other day and it was the same way. I miss my couch! :-D
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I admire you guys with the aluminum frame conversions because ( DONT HATE ME ) I also own a '00 Cr250 and the frame must've been built around the motor. It just seems like any time you want to work on it you have to tear almost the whole bike down. But in the end, these AF conversions all look sick.
Keep up the good work.
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Thanks for all the replies guys. This will be a slow project as I have 9 bikes to maintain and being laid off doesn't help.
I am going to try to have it ready for the start of my local Florida Trail Riders races. They start in late august.
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Looks like your off to a good start, is that a k5 swingarm? k5 shock linkage? what radiators honda? I imagine the motor is at the correct angle and the counter shaft sprocket is alignes with the rear sproket? I havent ridding a aluminum framed honda previous yeard were awesome for thier time, I hear the fame was very rigid didnt handle so well, just what I heard.? it would be nice to get a pipe not hammered on our cut and patched...I have spoke with AJ he seems to know what he is talking about...so his pipe advice my be good. I know JFAB also does some pipe work,,,,let me know how it goes THANKS
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It was a 500 swinger just for mock up purposes. I dont want to drill the 500 motor until I actually make sure I want to do this project.
I would cut the spacers to fit the stock CR swingarm when actually installing it and drill the 500 case to fit the swingarm bolt.
The sprockets look to be in line and there is enough room to shift the motor side to side if needed.
I have never ridden a CR except for my OLD 86 and 89 CR 80s I had as a teen lol. I got this CR with a cracked case and was going to fix it but thought it would be even better with the K5 heart in it. So I don't really know how it handles?
Anyone have any input on the handling??
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Thr Pre aluminum hondas handled great !!!!!!! owned a few. I cant believe how close that 500 engine is so close to fitting...even looks like there would be plenty of room for a desert tank.. makes you wonder if the honda 450 f frame is a closer fit also....do you know what year wast the last for the honda 250 aluminum frame and if they changed much?
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Kneedrager.
Any updates on the CR KX conversion?
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that would be bad then you can go cr500 hunting LOL
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you have to use the kx500 header and the cr 500 water jacket/expansion chamber and you have to dent the inside or weld it differently or it will not work look at my bike i did it