Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)

k5 klx 450r conversion

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Twosmokerfan:
Well everyone,

The end is in sight and the master of aluminium fabrication worked his magic on the weekend.  I have since dressed all the welds and you can't even tell there are inserts.

The master at work prepping the welds.


Welds complete (Right hand side)


Front


Welds cleaned up



Mounting of the MZB ignition on the LHS of the rear engine bracket


Engine installed and bolted up tight


Final exhaust clearance


I only finished this today, and everything else is going on the bike tomorrow. Hope to kick it over inthe next few days.

TSF

kwakman:
looks great.are those kx5 rads or 450 ones?

Twosmokerfan:
Thanks mate,

I bought a set of klx450 radiators off ebay and they are the 40mm deep ones.  I did this so I can still use KLX radiator braces as I race and ride in the bush, so am keen to use protection  :-D.

The standard radiators fit perfectly with the exception of the LHS lower water outlet.  I could have run the hose under the pipe, but decided to spin it upwards and over the cylinder head to meet up with the outlet from the other radiator.  I kept the water flow almost identical to the KLX set up, and even used the 'Y' piece to supply the suction side of the water pump.

TSF

kxpegger:
Looking forward to the ride report! Excellent work!

500donk:
Congrats on the build twosmoker!

Thats going to be a real head turner in the bush up there mate. Glad it all came together. That things the king of Enduro's.

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