KX Riders
Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: ToomanyKaws on March 30, 2010, 09:40:46 AM
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My frame was dropped off today with Jerrys frame rails, a mock up motor and a bunch of color pics from this site. I think we have most of it under control. Few questions though.
Where have most mounted the coil and ignition box?
As far as Radiator mods. Most move the left, (shifter side) lower radiator mount on the 450 frame up? And then mod the radiator mounting tab?
Any help will be appreciated. I have a lot of teardown pics. Can't wait to get the frame back and post up the projects progress.
thanks
Doug
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If you locate the frame rails fare enough forword you do not have to do anything to the radiator mounts, just put the tab back on the frame where it was after instaling the rails. I mount the CDI in the stock location and the coil on the left side near the fuel valve. You have to get the coil inboard enough or it will interfear with after market radiator braces. I hope the pics help.
JFAB
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Doug,
On mine SH left the radiator in the stock location and modified the lower tank area (removed some of the lower tank to clear the frame rail) and repositioned the lower hose connection.
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Other than geometry and looks, why put all the time and effort into going to an aluminum frame when it weighs more? Just curious...
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Other than geometry and looks, why put all the time and effort into going to an aluminum frame when it weighs more? Just curious...
You said it all...Superior geometry and outstanding looks! :-D
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Plus all the aftermarket parts you can get for the bike.
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Pure steering and handling.
It feels lighter in the air and more fliceble(or something like that).
And the looks/ coolnes of a AF :mrgreen:
And much more mordern suspension.
Dutchie
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All the reasons work for me. Guess I should put the '07 CRF 450 frame to use this year ;-)
Thanks fellas.
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Thanks for the pics Jerry. They will help out a lot.
Yes a lot of people tell me I am dumb to build such a bike. Don't really care what others think. Already have two KX500s I bought new.
Bought the 450 new. It handles different. To me for my weight it is very stable and straight tracking out of the box. Just not a four stroke fan. Stock motor had great power. Was a 4 speed which is not exactly ideal for the desert. Originally was going to use the 450 for the MX track, then ended up plating it up for the desert. But like the two strokes so much, bought a leftover 05 and 07 KX250s in the crates for the MX track. Plan to learn to ride MX a little better later on. Maybe race in the older folks classes when my skills get a little better on jumps and such.
So while I can ride my 02 KX500 in the desert. It will be nice to have the 450 conversion as a choice also. Have a KDX200 for the tight technical and or woods. And an older KX250 for track practice too. Nice to have options!!
Did a lot of car engine swaps when I was younger. Having a setup that not many others have is part of the intrigue. Just located a car for my next project. A Delorean.
We all see guys dump a ton of money in their new bikes only to sell them off cheap and start all over again with another. We all need hobbies.
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And I scoreds the motor! Thanks again! :-D
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My frame should be done in a week or two. It sat at the machinist for quite awhile before he got time to get on it last week. Will snap some pics when I drop off an ignition coil tomorrow. Still looking for another KX500 for a motor, carb, throttlw and ignition. Rest of the bike will be saved for a hill climb project. Can't wait to put the bike together with the borrowed mockup motor and atleast have most of it sorted out.
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Frame is about done. He is finishing the head mount yet. Will have to mod the one radiator yet myself. Here are some pics from a week ago when he was welding the cradle mounts on.
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Man U are going to have a nice bike when ur all done, But I am begging to think the 500 is to much bike, I almost looped my out a couple times at the track the other day, cant keep that front end down it comes up when it wants to!
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I have a 99, 02 and 04 KX500s. So this 06 KXF conversion will make sort of four. Frame is done, I just got to pick it up. Looks like the radiator will be only real project. Hopefully. Going to use the stock gas tank for now and get a Service Honda pipe for it. So the entire bike will be mocked up with this empty engine. :-D
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Picked up the frame yesterday and started putting some of the bike together. Need to get a pipe, and work on the left radiator. Then plumb everything up.
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More pics
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Few more
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Looking good Doug!
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Looks good don't forget lock-tight is ur friend on these bad machines!
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Radiators are good now. Need to have the lower outlet welded on the left side. Everything else clears. Now to get working on the airbox. Get a pipe and silencer and should have everything routed and plumbed. Course still need to find an engine for it. :-D
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Radiators are good now. Need to have the lower outlet welded on the left side. Everything else clears. Now to get working on the airbox. Get a pipe and silencer and should have everything routed and plumbed. Course still need to find an engine for it. :-D
It does not an engine, I just like LOOKING at it :-D
Great work Too Many, it looks like its going to be a fun ride!
DoldGuy
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Thats a fake 500 mockup motor. Just cases with a broken jug and head. Nothing inside it. Originally when I sold the 450f motor was to buy a 500 just for the motor. You know how that goes. Bought this 99 ex Team Green bike and want to keep it all in one piece. Its nice having another complete 500 to ride. In case the 2002 is down.
If I find a good engine for less than $800 will go that route. But really for the money can probably find a complete bike for $1200-1500 thats decent.
Right now need the carb, ignition box, coil and engine. :roll:
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Bought a 2000 KX500 to part out. Motor is supposedly new. Bike is kind of rough. Has new Moose rims and HD spokes. So those wheels are going on my 2002. Has really good compression. Will break the bike apart tomorrow and get the rear case enlarged for the swingarm bolt. Use the carb, coil and ignition off this bike. Also ordered the Service Honda AF pipe and silencer. Should be close to done and have it running in less than a month.
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Motor is drilled. Stealing the top end off this new motor for my 99 Team Green bike. Will have that 99 procircuit cylinder plated and new piston to put back on this motor for the AF. Service Honda pipe and silencer came. Few of the large dents they put in the pipe I don't need. So sending the pipe to piperepair.com to get some of them taken back out. Pipe fits decent. Water pipe off the jug is pretty close and will beed a bit of massaging. Will post some new pics this weekend. Getting closer. Least all the main fab work is done.
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do you wan to? to rent that mock up motor....great Idea, I was thinking about a jig but that would only get the motor mounts
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Still have to rebuild the other engine for it. And get the intake boot and carb fitted with the airbox. Did get the Service Honda FMF pipe and silencer for it and on.
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I want to do this bad! Maybe I'll try to find a cheap 125 or 250f and go to work while my motor's being re-built. Great job, your mockup looks great.
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I sent my engine off 2.5 years ago to be built. :oops: Asked for the engine back more than a few times along the way. I know where I am going on vacation soon though. Thats going to be interesting. What can you say. Some people cause their own problems.
So today I pulled the 20 hr engine out of my 02 KX500 and its being milled for the 18mm swingarm bolt. Hope to have the airbox and last radiator outlet moved and done and bike together in a few weeks.
Will post some new pics soon.
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I sent my engine off 2.5 years ago to be built. :oops: Asked for the engine back more than a few times along the way. I know where I am going on vacation soon though. Thats going to be interesting. What can you say. Some people cause their own problems.
So today I pulled the 20 hr engine out of my 02 KX500 and its being milled for the 18mm swingarm bolt. Hope to have the airbox and last radiator outlet moved and done and bike together in a few weeks.
Will post some new pics soon.
I think we have found some more of your secret Searchlight trails on the southeast side a couple of miles outside of town. You still riding with Nick? Haven't seen you post here for a long time. Thought maybe you had quit riding? Got a new phone and lost your number.
Pete
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Bike is all together. Waiting on new chain and sprockets. Need some desert gearing. Right now got an 02 KX250 airboot sitting with the stock airbox. Have a 2000 CR250. Not sure which one I will use. Like how the KX boot clears the shock for the most part.
Few coolant lines to hook up yet. Can't see to upload pics on here... :-o
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Down to just the airbox. Got the subframe and box back off. Working on it. Ugghhh. Rest of bike is all done. Welded two skidplates together and came up with one that protects everything. All the cooling lines weren't that bad. Good call on the gates 180 hose. Waiting on the chain and sprockets to come in. And the pipe guard.
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Bike is done. Need to photobucket up some pics. Still trying to find a carbon CR500 pipe guard. No luck finding one in stock anyplace online yet.
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Bike is done. Need to photobucket up some pics. Still trying to find a carbon CR500 pipe guard. No luck finding one in stock anyplace online yet.
ELine did have them listed at their site but no longer. You may want to contact ELine. The P/N for Eline is HPGH25, FMF 1989-2001.
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Here is my finished AF. (http://i40.photobucket.com/albums/e209/toomanykaws/IMG_4269_zps734af3d1.jpg) (http://i40.photobucket.com/albums/e209/toomanykaws/IMG_0847_zpse90303b5.jpg) (http://i40.photobucket.com/albums/e209/toomanykaws/IMG_7723_zpsa4e7f7e1.jpg) (http://i40.photobucket.com/albums/e209/toomanykaws/IMG_3086-Copy_zps32196203.jpg) (http://i40.photobucket.com/albums/e209/toomanykaws/IMG_6538_zps4ed3aeff.jpg) Still looking for a carbon pipe guard. So its not trashed the first time I ride it in the desert and shake it down.
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wow, that thing's beautiful Toomany!!...looks like it came from the factory that way, nice job!!
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Thanks. :-D This bike was new and only has 9 hours on it when I cut it apart. Going to change graphics yet. Pics don't have the new chain and sprockets I just put on. Building a second frame now. (http://i40.photobucket.com/albums/e209/toomanykaws/IMG_9416_zps7b984d90.jpg)
May have this one heat treated and anodized or powdercoated black. My other frame was oven heated and carefully welded. And I don't plan to jump 100 footers. So it should be fine. Will look for some 06 and up suspension to get started on this new project.
Borrowed the mockup motor from my buddy again. Same old machinist is going to do this frame.
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nice that more n more people are doing that now im gonna wait till my crf 450 blows then stick a 500 in lol..
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Looking forward to a ride report and HD video :-D
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Bike is all together. Waiting on new chain and sprockets. Need some desert gearing. Right now got an 02 KX250 airboot sitting with the stock airbox. Have a 2000 CR250. Not sure which one I will use. Like how the KX boot clears the shock for the most part.
Few coolant lines to hook up yet. Can't see to upload pics on here... :-o
Not sure why mine is so much different but the 2000 CR250 boot wasn't even remotely close on mine. I ended up modding the stock 2006 KX450F airbox and using the stock 500 boot. I also couldn't fit a 450F radiator on the left side, pipe interfered too much. I ended up using a 2005 CR125 radiator on the left.
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I used the stock 450 radiators. The left, had the lower pipe moved and the guy welded it in the wrong spot. It works but doesn't have the angle or routing I would like.
The 02 KX250 airboot I got. Just didn't like how it was around the shock. The Honda boot was a bit smaller. Running a reed spacer so my carb is back a bit more than stock. And the Honda boot lined up. Made an adapter plate for the stock 450 airbox. See if I got a pic of the box all bolted together but off the bike.