Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
My 2009 KX500AF [picture heavy] (SHE'S DONE!!!)
kxpegger:
It was the air boot to air box flange bolt that rubs the shock housing near the top. SH knew it was a clearance problem because they had shaved it down to almost nothing. About every year or two I put some JB weld on the rub spot on the shock housing and some RTV on the bolt. Problem solved but I have to stay on top of it. I don't think you will have the same problem with the KX boot mod vs the CR250
FL_Sharpshooter:
--- Quote from: umberto on August 21, 2016, 12:53:43 PM ---Great looking build FL_Sharpshooter! Please keep the pictures coming.
I also got my Lectron from Packard Racing and had the same issues you are having with the cable and new throttle. I eventually made mine work with some redneck engineering, but it's nice to know that you can buy the stuff from Lectron. Thank you for posting your experience.
--- End quote ---
Thanks for the encouragement. You've built a really nice conversion as well. I'll definitely be boiling my new intake boot to the Lectron as you showed in your build thread, thanks for the idea. I saw the problem with your throttle, looks like you came up with a reasonably good solution, nice job. I have noticed that you as well as some others are using the kx250 throttle with your 500. Is there really that big a difference in throttle feel to justify me buying a whole new assembly? Just curious...
--- Quote from: kxpegger on August 21, 2016, 01:46:07 PM ---It was the air boot to air box flange bolt that rubs the shock housing near the top. SH knew it was a clearance problem because they had shaved it down to almost nothing. About every year or two I put some JB weld on the rub spot on the shock housing and some RTV on the bolt. Problem solved but I have to stay on top of it. I don't think you will have the same problem with the KX boot mod vs the CR250
--- End quote ---
Ah, I see now. I don't think that will be an issue at all with the kx250 boot. Well, I guess SH (or any manufacturer for that matter) can't possibly think of everything. Good idea with the jb weld and rtv, you gotta do what you gotta do sometimes. Have you thought about fitting a different boot? Might save you some frustration and future work.
umberto:
--- Quote from: FL_Sharpshooter on August 21, 2016, 02:10:03 PM ---
--- Quote from: umberto on August 21, 2016, 12:53:43 PM ---Great looking build FL_Sharpshooter! Please keep the pictures coming.
I also got my Lectron from Packard Racing and had the same issues you are having with the cable and new throttle. I eventually made mine work with some redneck engineering, but it's nice to know that you can buy the stuff from Lectron. Thank you for posting your experience.
--- End quote ---
Thanks for the encouragement. You've built a really nice conversion as well. I'll definitely be boiling my new intake boot to the Lectron as you showed in your build thread, thanks for the idea. I saw the problem with your throttle, looks like you came up with a reasonably good solution, nice job. I have noticed that you as well as some others are using the kx250 throttle with your 500. Is there really that big a difference in throttle feel to justify me buying a whole new assembly? Just curious...
--- Quote from: kxpegger on August 21, 2016, 01:46:07 PM ---It was the air boot to air box flange bolt that rubs the shock housing near the top. SH knew it was a clearance problem because they had shaved it down to almost nothing. About every year or two I put some JB weld on the rub spot on the shock housing and some RTV on the bolt. Problem solved but I have to stay on top of it. I don't think you will have the same problem with the KX boot mod vs the CR250
--- End quote ---
Ah, I see now. I don't think that will be an issue at all with the kx250 boot. Well, I guess SH (or any manufacturer for that matter) can't possibly think of everything. Good idea with the jb weld and rtv, you gotta do what you gotta do sometimes. Have you thought about fitting a different boot? Might save you some frustration and future work.
--- End quote ---
Thank you for the compliment on my bike. It's been a lot of fun to work on for sure. Of course I couldn't have done it without the help I've received from the guys on this site.
I used the KX 250 throttle mostly because it's what I had. I've been happy with the throttle action though. I've never actually ridden a later model stock 500 (my last ride was on an 84 air cooled), so maybe one of the other guys can comment on why to switch to the 250 throttle.
I can't wait to see your ride videos. It should be a very nice ride when you get it done.
kxpegger:
I have but then I'm lazy! Would just rather put a band aid on it and ride so long as it works... not recommending that though!
FL_Sharpshooter:
--- Quote from: umberto on August 21, 2016, 02:57:09 PM ---
--- Quote from: FL_Sharpshooter on August 21, 2016, 02:10:03 PM ---
--- Quote from: umberto on August 21, 2016, 12:53:43 PM ---Great looking build FL_Sharpshooter! Please keep the pictures coming.
I also got my Lectron from Packard Racing and had the same issues you are having with the cable and new throttle. I eventually made mine work with some redneck engineering, but it's nice to know that you can buy the stuff from Lectron. Thank you for posting your experience.
--- End quote ---
Thanks for the encouragement. You've built a really nice conversion as well. I'll definitely be boiling my new intake boot to the Lectron as you showed in your build thread, thanks for the idea. I saw the problem with your throttle, looks like you came up with a reasonably good solution, nice job. I have noticed that you as well as some others are using the kx250 throttle with your 500. Is there really that big a difference in throttle feel to justify me buying a whole new assembly? Just curious...
--- Quote from: kxpegger on August 21, 2016, 01:46:07 PM ---It was the air boot to air box flange bolt that rubs the shock housing near the top. SH knew it was a clearance problem because they had shaved it down to almost nothing. About every year or two I put some JB weld on the rub spot on the shock housing and some RTV on the bolt. Problem solved but I have to stay on top of it. I don't think you will have the same problem with the KX boot mod vs the CR250
--- End quote ---
Ah, I see now. I don't think that will be an issue at all with the kx250 boot. Well, I guess SH (or any manufacturer for that matter) can't possibly think of everything. Good idea with the jb weld and rtv, you gotta do what you gotta do sometimes. Have you thought about fitting a different boot? Might save you some frustration and future work.
--- End quote ---
Thank you for the compliment on my bike. It's been a lot of fun to work on for sure. Of course I couldn't have done it without the help I've received from the guys on this site.
I used the KX 250 throttle mostly because it's what I had. I've been happy with the throttle action though. I've never actually ridden a later model stock 500 (my last ride was on an 84 air cooled), so maybe one of the other guys can comment on why to switch to the 250 throttle.
I can't wait to see your ride videos. It should be a very nice ride when you get it done.
--- End quote ---
I see, I was thought maybe there was a specific reason for you using the kx250 throttle. I should be fine with the stock 500 throttle. I remember riding the bike in stock form, I don't recall the throttle being an issue. Thanks for the compliment! I would say I'm about a month or two from it being done/up and running, possibly even sooner.
--- Quote from: kxpegger on August 21, 2016, 03:14:14 PM ---
I have but then I'm lazy! Would just rather put a band aid on it and ride so long as it works... not recommending that though!
--- End quote ---
Well, there's nothing wrong with that! :-D
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