Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
'09 500AF build
hulkteam476:
Have you checked if the engine went out? with the fourth carrier. after being welded.
sandblaster:
Wow!
That is a beefy head stay.
It will be interesting to see if either one of us experience the cracked down tubes that some have had without the front head stay.
I'm betting no but time will tell...
jBernard:
--- Quote from: hulkteam476 on June 26, 2014, 03:41:50 AM ---Have you checked if the engine went out? with the fourth carrier. after being welded.
--- End quote ---
yes, looks like its not to hard to get the engine in there. I'll leave the swingarm pivot in, and take all other brackets and mounting bolts out. Rotate the engine back so head is close to where the tank area is and pull head and cylinder off. then bottom end can be removed and removed thru the side of the frame. Would be nice to fit the completely assembled engine thru the frame but no way thats going to happen.
jBernard:
Had to go ride some downhill mountainbikes in Colorado so sorry for the lack of updates :-D
Here's a quick update pic though...
Getting close to tackling the hydraulic clutch retrofit. Stock pushrod isnt going to work (not long enough), so I had a piece of Ti 6AL4V-ELI precision ground down (+-.0002! d**n!) for a custom length rod.
Don't know why the stock rod is waisted. If i had to take a guess its so they could turn down the ends on a lathe for precision and not have to worry about the whole thing, since it only needs to be tight fit on the ends where it mates to the bearings.
NO idea how I'm (or rather Tom Morgan when he goes to build this engine) is going to find out how long to make the rod for proper engagement but I'll worry about that later.
jBernard:
Hey all. Bit of a long overdue update. Have a few things arriving back from the 3d printer tomorrow, so once they check out on fitment its off to get made and some more progress completed. Here are a few Solidworks screenshots of a few revised parts:
- Front headstay head mount (laser cut Ti with welded uprights)
- front headstay frame mount (chamfer for welding recess
- HPSD frame mount
- KIPS front cover plate (will be laser cut Ti)
- Rekluse Slave cylinder spacer/case mount
- Swingarm spacer tabs (laser cut Ti)
Will post an update when I have some of these parts fitted/made as well.
For now heres a shot of current state of the bike. it 'sort of' looks more like a motorcycle! dont worry, yellow shock spring is getting powdercoated blue. Just need to make sure its still the right spring ratio before I coat it!
I've gotten ahold of '13 Brembo full front and rear brakes, and a hydraulic clutch! So the controls on this bike are going to be top notch!
stay tuned!
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