Maintenance & Technical > Kx Frankensteins

YZX500 Project

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scottysg:
Updates today! Been really busy with work this month. finally got time to jump on this project. No mods have been done to the frame. The KX fits with the rear axle and lower engine bolt lining up. will need to modify the head bracket and make some adapter for the front engine bolt.

scottysg:
Last night I used a dremel, a file, and tap magic to remove 0.315" from the inside chain side of the swing arm because the kx motor is quite a bit wider at the rear mount that the yz motor. Test fitted, and the sprocket looks like its centered pretty good with the rear sprocket. But there should be a slight gap between the swingarm and the engine. So I will remove material to get to .375" total material removal. This is very easy to do, just slightly time consuming.

Now the holdup and the hard part is removing this 0.375" from the bearing pin. I couldn't even scratch that with my fancy file, it is extremely hard material. Ill have to take that to a machine shop to throw on a lathe. I found a bearing online that will replace the 2 bearings that are currently in each side of the swingarm, except of course it is .375" shorter that the 2 oem bearings total width together.

Once the rear mount is sorted out, I can move on to the front mounts. Then figure out what carb I want to run.

As a side note, there is a slight bit of slop on the flywheel. Like its not tight on the crankshaft and it rotates until the key stops it. I don't have a flywheel puller for this yet but if you guys think thats pretty weird Ill have to just pull the flywheel and make sure the key isn't sheared then lap the crank and flywheel to fit more snugly.

Any thoughts or suggestions are appreciated. I don't know what I'm doing here :)

scottysg:
Last night I was able to ream the hole in the engine. used a grizzly 43 64 drill bit. (17.07mm, I read about this on the forums as a good overbore to allow clearance, not my idea) sorry my slash button is broken on my computer. its a hss chucking reamer so it was easily able to bore the hole in the soft magnesium. I also started removing .25" of material from the clutch side of the engine mount, so as to let the engine fit in there. I got tired and wanted to eat before I got all the way to .25". I have .125" to go. Unfortunately I am an idiot and in my stupor didn't realize that the swingarm bolt changed from 17 to 18mm from '01 to '02, which my bike is, so the swingarm pivot bolt still doesn't fit in. So I ordered a 23 32 chucking reamer (18.25mm)to bore it again to the next size.

Also, I removed the flywheel, used some valve lapping compound and worked the flywheel on the crank. both the flywheel and crank had surface rust. Now they're polished clean and after a hit with a mallet, it is locked on there. stator looked good, though i have no experience with kx500s so that comment is pretty useless.

Waiting for parts or tools sucks!! Its so close, the hole is going to be very clean indeed. Today i should be able to finish cutting the motor and getting it fit in the swingarm. Cant wait to get this rear mount figured out and get going on the other mounts. hell i can't wait to spark it up.

Im just lost with how I want to fuel it. I have the kx500 carb and the yz250 carb. But I've read that 500's are hard to tune (and I'm nothing special at carb tuning) and I'm trying to spend my time riding not tuning. not to mention if I'm riding at gorman its freezing then I go to barstow or ocotillo and its 100 degrees out. because of that a lectron sounds very appealing. If any one has some advice on this matter, Id appreciate it. Pics to come tonight.

umberto:
I have a Lectron on my 525. If you are riding that varied of conditions, it's right up your alley. There are only two adjustments, the needle for open to 1/2 throttle, and the power jet for 1/2 to full. It takes minutes to tune, plus they can get it pretty close from the factory. I bought mine from Packard racing. I have a post on my 2003 conversion showing what mods I did to get it installed.

ozrider:
now you need black plastics and paint frame green  :-D

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