KX Riders
Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: kawiboy63 on December 27, 2009, 08:54:40 AM
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has anybody built a klx450r/kx 500 yet? it would be so sick if i could find a roller id build it with the enduro set up and headlight and all
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Hi Kawiboy63,
I am in the process of doing it now. I am just sourcing the KLX and then will do the engine swap. Have the donor engine, and done a lot of research on the electrical system, as I still want to keep it street legal. Just re-built the K5 engine and tuning it now. You will have to watch this space, and I will document everything for all to read when I have finished.
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Well, I just picked up my 2008 KLX450 and took it for a ride. Awesome bike and I am really looking forward to the conversion. Turn really nicely, but the suspension is where it needs work.
Looks like the only issue I will have is the electrical system, but I will let everyone know how it goes.
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Any update on this project?
Bob W
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Update as follows:
Engine finished with new ignition (Powerdynamo).
KLX chassis being stripped and cleaned.
Brackets being welded in the next few weeks.
It has been taking forever due to lack of time (haven't even had time to ride my Gas Gas EC300, although I did trial fit up the engine in the frame and it fits quite well, to the point where I almost decided to use the Gas Gas Chassis).
Electrics being finalised now while I am waiting for the chassis to be finished.
Sorry about the delay guys. Kids and University study take up a lot of time.
TSF
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Update:
Chassis stripped and cleaned. Off to the fabricator this weekend.
Service Honda exhaust and muffler, along with hose kit has arrived. Very nice I must say. I chose the Q series spark arrestor so as not to attract attention on the road.
I am taking lots of pics, and will figure out the attachment process when I get a chance.
Interestingly, the KLX looks like it doesn't need any radiator modifications. Just swapping of the hoses around and using the T piece and Y piece to have the water come up on the left hand side (as the KLX has it on the right).
Electrics are being modified while the chassis is away. Most of the wiring loom looks like it will stay to keep all the horn, indicators, headlight and switches. It will be ready for the electric start on the KX engine when I get the chance to look and design something (have to calm the wife down first)
Thanks for everyone's help so far on this site. You guys (and girls) are the best.
TSF
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if anyone is interseted and in the uk ,when i was looking for a donor chassis for my jan de groot motor corby kawasaki in the uk had a klx 450 rolloing chassis ,not sure if they still have it though!!!
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Hi everyone,
I have bee busy over the past few weekends and now have some pics to show. Everything is now tacked in place and all brackets made.
All aligned and I will be welding it up in the next few weeks. I can't wait.
The airbox is 90% finished using a 89 KX250 air box boot. Lines up pretty nicely.
This was the starting point
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120115-00188.jpg)
I used the original KLX lower engine brackets using 2 spacers from the KLX front engine brackets.
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120206-00297.jpg)
Interestingly, the KLX engine weighed in at 33kgs, and the KX500 weighed in at 27Kgs.
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120117-00216.jpg)
Muffler and Bracket
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120131-00293.jpg)
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120131-00292.jpg)
Clearance of the SH Pipe and dummy fitup
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120130-00283.jpg)
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120130-00282.jpg)
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120130-00281.jpg)
Top view and the MZB ingnition. I am lucky with this as the CDI and coil are in one unit. Meaning that I only have to find a place to mount the one item and not two.
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120206-00300.jpg)
More pics to follow.
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Looking good :wink:
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good work TSF, I've just moved so after decorating I can go beserk as for the first time in 6 years I have somewhere indoors thats warm to work in where wifey can't moan.result! K.
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looking sweet !!!
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Pics from today:
Front with brackets for front engine mount
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120217-00313.jpg)
RHS of frame with the inserts
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120217-00312.jpg)
Inside airbox with adaptor plate for 89 KX250 air boot. Needs no spacer plate and clears the shock except the very top, but I should be able to adjust it to not touch.
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120217-00317.jpg)
Carb alignment with air boot
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120217-00319.jpg)
Close up of frame mods and clearance to Power valve cover.
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120217-00315.jpg)
Well, I now am playing with the electrics and have to find a spot to mount the ignition (not a problem), along with figuring out how to trick the main relay into thinking it is still a 450.
The frame is being welded up this weekend on Sunday, and then the final assembly begins......
TSF
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Very nice, this is what I need to do to mine.
Bob W
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Looking good TSF, how did you find plumbing up the ignition??
I'm still sitting on my ass, yet to get a frame, but we are keeping an eye out.
Haven't even had a ride since mid Jan, just to busy with work and family !!
Will keep an eye out for more pics.
Cheers
Grant
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Hi Grant,
That KLX frame I spoke to you about is still here and for sale if you want it.
The electrical system doesn't seem to be too hard at the moment. Your do need the MZB ignition to run all the KLX extras and the 55/60 watt headlight and all the road gear. I am keeping the battery for the moment, and the MZB (as you know) comes with the reg/rect and that will be hooked directly up to the battery.
The KLX runs a main relay that closes once the engine is running, and I will need to trick that relay, as i don't won't the full power going through the key ignition as my guess is it will toast it.
I am keeping track of the project and will do a write up for those that wish to convert a KLX with the KX5 engine. This will include the electrial mods.
TSF
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Well everyone,
The end is in sight and the master of aluminium fabrication worked his magic on the weekend. I have since dressed all the welds and you can't even tell there are inserts.
The master at work prepping the welds.
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120226-00349.jpg)
Welds complete (Right hand side)
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120227-00351.jpg)
Front
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120227-00352.jpg)
Welds cleaned up
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120227-00353.jpg)
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120227-00354.jpg)
Mounting of the MZB ignition on the LHS of the rear engine bracket
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120227-00356.jpg)
Engine installed and bolted up tight
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120227-00357.jpg)
Final exhaust clearance
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120227-00358.jpg)
I only finished this today, and everything else is going on the bike tomorrow. Hope to kick it over inthe next few days.
TSF
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looks great.are those kx5 rads or 450 ones?
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Thanks mate,
I bought a set of klx450 radiators off ebay and they are the 40mm deep ones. I did this so I can still use KLX radiator braces as I race and ride in the bush, so am keen to use protection :-D.
The standard radiators fit perfectly with the exception of the LHS lower water outlet. I could have run the hose under the pipe, but decided to spin it upwards and over the cylinder head to meet up with the outlet from the other radiator. I kept the water flow almost identical to the KLX set up, and even used the 'Y' piece to supply the suction side of the water pump.
TSF
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Looking forward to the ride report! Excellent work!
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Congrats on the build twosmoker!
Thats going to be a real head turner in the bush up there mate. Glad it all came together. That things the king of Enduro's.
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Thanks Mate. I sure it will turn heads at the trail rides and enduros I go to. I thought you were going over to the Carribbian (spelling?). You back up north or in Sydney?
Now all I have to do is get the decomp valve and the electric start sorted (letting the wife calm down first) then I am all set. That is the next project on the KLX, and just think the Battery and charging system is all there ready to go.
Riding it at the Gympie Trail ride this weekend and fine tuning it.
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Yeah Kim in the Caribbean. Had a ride of the af before christmas in Sydney though. It got the blood pumping after not riding for 6 months before.
Electric start on a 500, what a luxury! Is there anyway that she can be rego'd up there? Enjoy the riding anyway mate.
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Well Ladies and Gents. Final Pics are here. Rode it at Killarney Border Ranges Trail Ride on the weekend, and all I can say is OMFG.
This thing is a monster. I had a mate on a late model WR450, 3rd gear roll on, and he had no chance. It is the torque monster. The ride was very wet in places and the 4T lovers were boiling bikes, and stuck on hills, but the KLX500 just chugged up hills. I chose 14-50 gearing (mainly because the KX had a 14t, and the KLX had a 50t on the rear), and that was perfect, if not a tad high for the single track.
I have modified a wiring diagram to help those that want to do the same with a KLX. The weight difference is very noticable and the KLX is more manageable (in a weight sense) that the 4T. One thing though, ye must respect the right hand, as it gets up and really moves without revs.
I would recommend doing the conversion if you can get your hands on a KLX. On thing though, it absolutely sucked the juice. I was flat our getting 40km out of 7litres. I might need to check the carby, as it wasn't oiling up the plug, but it was definately getting too much fuel.
Here are two pics of the finished product.
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120322-00381.jpg)
(http://i1056.photobucket.com/albums/t377/TSF500/IMG-20120322-00382.jpg)
One question I do have is, Has anyone used a 38mm air striker carb? If so, what difference does it make?
Thanks for all the help. I will put togeter a build guide when I finish some assignments first.
TSF
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awesome ...cant say much more.
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TSF, That is awsome, good to see the beast finished.
As usual, Bike parked up since Jan, too busy to ride...bla bla bla..... :mrgreen:
Will need to get onto this conversion this winter, just need the $$$$$ KXF's are just about being given away over here now !!
Cheers
Grant
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Very nice job!
My K5's all suck a lot of juice.
I think your mileage is about par.
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Awesome build!
These af builds are a real work of art!