Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
1990 KX 500 to 2006 KX450F Conversion Project
Kwackerman:
Hey guys, I'm new to KX Riders, but I've been riding, racing, and wrenching on Kwackers for many years. I own a 1990 KX 500 that I've been racing since my Dad bought it new for me as a Christmas present in 1992. I love her and affectionately refer to her as "The Beast." I've primarily used her for enduro and hare scrambles riding in the southeast and Midwest. I know, I'm crazy, but she goes really good in the woods, despite the awesome power. It's all about throttle control and short shifting.
I purchased a 2006 KX450F roller off eBay a year or so ago and I finally got tired of looking at it sitting in the garage and decided to do this project. Unfortunately, I had to sell my 2007 KX 250 to fund the job, which was very painful. In the end, I think I'll be glad for marking this off my bucket list if nothing else. I mailed my 450 frame along with the engine mounts and radiators off the 500 to George Fanelli (some of you may know him) at MPS Racing in Monclova, OH. He's very experienced at doing these conversions and he's going to mod my frame and provide me with an airbox adapter and custom Dynaport pipe. I should get all that back from him in a couple of weeks and then it'll just be an assembly project after that.
I wanted to attach some pics of the olé girl in modified/stock form with all the little goodies I've put on her over the years, so you can see she's already pretty formidable, but I haven't figured out how to post a pic yet. I'm going to part her chassis out, so if you know anyone with a stock KX5 who would like to upgrade their bike on the cheap, I'll post some information about all the stuff I'm selling too. I'm not looking to raise funds as much as I'd like to help someone else improve their KX5 experience, so it'll be inexpensive.
I'm really looking forward to this build. I'm going to make sort of a time lapse YouTube video of the build too, starting with the bare frame. Hopefully that'll be pretty cool too. More to follow in a couple of weeks, Howie
sandblaster:
Hi Howie and welcome to the best K5 forum on the net.
You can post pics like this:
http://www.kxriders.com/forums/index.php/topic,10040.0.html
If you can't figure it out email me the pics to oem-cycle@comcast.net
Be sure to include your user ID or the thread title "1990 KX 500 to 2006 KX450F Conversion Project"
That way I'll know where to post the pics when you send them.
Can't wait to see what you do on this project.
Kwackerman:
Sandblaster, I tried to email you some pictures, but they wouldn't send. I'll get that figured out, soon I hope.
A couple of quick updates: I removed the head and mailed it to Larry Wiechman in Roscoe, IL yesterday morning for the decompression mod. Considering I nearly ripped my right calf off in Germany trying to start the beast wearing a pair of Merrill's (stupid idea) and couldn't ride for two months while my leg recovered, I'm really looking forward to that magic little button.
I have also ordered about $1,500.00 in assorted parts and accessories so as soon as George gets my frame mod done and sends it back (should be by Halloween or there abouts) all I should have left is a big bolt together party. I'll probably miss the first race of the winter hare scrambles series here in MO, 2 Nov, but I should have the beast running in time for round 2, 9 Nov.
I do have one question: What's the best way to bore the engine cases out without disassembling the motor, or should I not try that? The KX450F swingarm bolt is a couple of millimeters bigger than the stock KX5 bolt. I'm thinking I'll get someone to help me hold the motor on the drill press and just bore it out. Is it that simple or am I setting myself up for trouble?
sandblaster:
I drilled mine out one at a time using a 43/64" bit.
Worked like a charm.
Kwackerman:
OK, thanks. Sounds good, I'm just lazy and didn't want to split the cases unless I absolutely had to...
Thanks for the tip on the drillbit size too. I haven't had time to measure that yet.
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