Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
'09 500AF build
jBernard:
thanks for the kind words :)
i thought about the Ride caliper. IMO, its a bit ugly with the logo on the side so prominent. but the cnc work is very nice. this is purely just my opinion though as i'm super anal, cause i still think it looks nice, and the guys at Ride are good people.
and it IS a good bit lighter than a stock caliper so that is nice.
I'm going with brembo retrofit for a few different reasons:
-got a caliper for 100$ each, cant beat that
-brembo freakin rocks, tried and true. i love it on my KTM and thats with stock pad and rotor. will be way stronger setup on the AF
-getting them cerakote'd the same color as the factory calipers so will look even better
-ride caliper is only on the front. wanted something to match f/r
i thought about EFI for a bit. actually did a good amount of research and got a throttle body from a kxf450, was about to pull the trigger on a microsquirt setup and start messing with it.
few issues made me bail on it:
-weight vs a carb. would end up adding 5+ lbs i bet
-lots of time tuning. only way to do it right would be on a dyno with a true AFR tune and that = time and $
-possibility of doing all that and results marginally better than a 300$ carb
-would cost 1k+ doing it right and not hack job
the banshee guys and the rz350 guys have done this before, and on 2T so a bit of the guesswork has been figured out already for you. and the consensus is....has cool perks but people still like the carb. thats what i can gather.
Kraemer864:
Wow! Awesome build! Im currently building a 2012 kx250afc with a 04 kx250 motor. Im looking for someone that makes yokes and a headstay mount. How much would it cost if you were to build that yoke for me? Also what angle did you bend the frame rails to? I have the tubing to make the frame rails but I dont know what angle to bend them to. Thanks!
jBernard:
Thanks!
I have an extra headstay (shock mount frame area to back headstay mount) I'd sell, I'll PM you a picture of it later tonite. And I have had a few people wanting yokes as well. The design needs a slight revision before I want to machine up another set of them though, they were way to beefy wall thickness for my liking. Just cosmetic, but I'd like it to flow a bit better on the next revision.
On the frame rails, I made my yoke up first, then fit it into the frame and clamped it in, then put the engine in and mounted it via a solid point (swingarm bolt) in the back, then just rough set my engine angle by putting blocks under the cases. You want the engine as low as you can mount it, but still have easy to mount engine mounts. (Thru holes in the cases cant be below or equal in height to frame rails, ect).
Here's a photo of how i roughed it out.
Then I just made a rough paper template from the side (1" tube profile). Cut that out, then took it to the bender. We just got as close as we could to the paper template, with plenty of excess straight tubing to trim off later. Then at the welder we tweaked it into final position.
One big thing i'll do next time is fill the tubes with sand and cap them. Walls on the tubing started to deteriorate the last couple degrees. Also use tubing with a high radius corner. If you look at the new CRF's, the tubing they use on frame rails is almost hex shape its got so much radius. This is a better design for load than a square tube with no corner radius.
I'm going to play it safe and beef up the support to the top engine mount from the yoke before I heat treat to make up for this.
Kraemer864:
Awesome thanks! I am getting the tube aluminum bent tomorrow and I was planning on using sand to stop the tube from creasing. The headstay would be awesome I could really really use that!
RoostiusMaximus:
The 09+ crf chassis bikes are 5 sided tube :wink:
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