KX Riders

Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: bruuuuup on July 11, 2010, 09:38:54 AM

Title: 500 progress pics!
Post by: bruuuuup on July 11, 2010, 09:38:54 AM

Heres my 2009 KX250F bike, the motor was a tight fit but I got her to work with the factory Y piece in the head stem with some modifying of course. Man what a giant motor this thing is, now I am on to making some motor mounts for it and hopefully the motor will still come out after there welded in :?. I already got the airbox ready to go so all thats left is the rads and some mounts for the motor and pipe not to much longer I dont think. I traded the 09 250f motor that was in the bike for a 97kx500 motor that mcr suspension had (a local race shop) . They rebuilt the hole thing matched the cases ported it out v-force3, brand new everything from the crank and piston even the whole tranny so it should be a really nice unit. I will post more pics when its all done!
 
(http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs079.ash2/37294_136953589658784_100000324322113_262447_7756865_n.jpg)

(http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs079.ash2/37294_136953566325453_100000324322113_262441_1371308_n.jpg)

(http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs139.snc4/37294_136953569658786_100000324322113_262442_6135766_n.jpg)

Title: Re: 500 progress pics!
Post by: kxpegger on July 12, 2010, 12:25:41 AM

Looks like your off to a great start! What did you use for frame rails? They look like they're still one piece?

Title: Re: 500 progress pics!
Post by: bruuuuup on July 12, 2010, 02:49:50 AM

I used j fabs rails but I had to use them backwards cause the 250f frame was a lot diff. But it turned out looking perfect.

Title: Re: 500 progress pics!
Post by: jbersano on July 12, 2010, 03:00:09 AM

Great Project!!!!!!!!!!!!!!!!!!!  :mrgreen:

Title: Re: 500 progress pics!
Post by: BDI on July 12, 2010, 04:11:28 AM

Very cool. thank you for posting your build pictures. I know it's easy to forget to take pictures as you go but it sure is a huge favor to the rest of us. what kind of amperage did you find yourself welding at if you don't mind.

Title: Re: 500 progress pics!
Post by: 570mitch on July 12, 2010, 06:26:15 AM

Welding looks excellent, admire you taking on the 250 frame. They all say it's a big job compared to the 450.

Title: Re: 500 progress pics!
Post by: bruuuuup on July 12, 2010, 08:27:22 AM

I had a friend do the welding he has a syncrowave 350 I think.  he put down one main weld everywere and then double lapped them as well, I will take better pics of just the cradle when I take the motor back out for the motor mounts It looks pretty factory, And the 250 frame is WAY smaller then the 450, It took me a long time to get the motor in the position I wanted it in it has about .020" from the front of the motor to the head stem I had to take out little by little to get it perfect.

Title: Re: 500 progress pics!
Post by: jbersano on July 13, 2010, 06:28:05 AM

Hi!, great project... what radiator hoses was used? model? thanks!!!!

Title: Re: 500 progress pics!
Post by: bruuuuup on July 13, 2010, 10:07:36 AM

I got the hoses from service honda they look pretty cool.

Title: Re: 500 progress pics!
Post by: brooksie on August 03, 2010, 08:07:45 AM

Any more updates? I'm about to start on the very same conversion and any advice/help would be much appreciated!

Cheers