Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
KX500PF
cutting torch:
The PF is for perimeter frame, since I could build a stock KX500 and it would be an SF. :-D
I finally got to the point where I could start this project.
The chassis is a '92 KX250 which was my primary ride for over a dozen years. I scored an '08 KLX450 front end for it on Ebay. The engine donor bike was an '87 KX500, but I have since gotten enough stuff to make the engine an '89 to '04.
This bike will be used for trails, not MX, and since I am about a 7/8 scale man, I will mod the clutch cover for a Rekluse Pro.
Enough with the background. I started the basic engine mounting a few days ago. I bored for the swingarm bolt as a starting point to get a baseline. Obviously, the front mounts were not even close:
Before and after them being cut off:
The mockup before welding:
After the welding:
The lower mount was so close to where it needed to be that I decided that it was a waste of time to try to move it like I did the front mount. I could have left it alone and used an 8mm bolt, or shave it a bit oval (.020") to use a 10mm bolt. I went with the ten.
I have learned a bunch from this site, and now is the time for me to start contributing! Any questions for me will be answered to the best of my knowledge. Any suggestions that I get are welcome as well!
torch
ZETTNORCAL:
COOL!!!! 8-) 8-) 8-)
junk man:
looks like your off to a good start. :-D
WRXBRUMBY:
Ok just hang on a minute while I go and get the popcorn :wink:. I will be watching this one closely.
?and since I am about a 7/8 scale man? (is this short :?) soz im in Australia and we have only metric system jokes hehehehe
Also Rekluse Pro......I assume this is the Z-Start pro with full clutch override at all rpm?
Please classify what parts of what clutch kit will be needed to do this, or is there one complete kit that will fit for KX500 after the cover mod has been done to use the Relkuse Z-start Pro?
Don?t mean to bust your balls bud, just I would really like to see the Z-start Pro work. Its just that I have read that only the Z-start has been used in the past and even this was a miss match of parts from I think the DRZ400 kit???
Posted by gortex http://www.kxriders.com/forums/index.php/topic,6250.15.html
?To use the Rekluse - you use the stock kx500 clutch, and buy the Rekluse start for the Drz400/Klx400. These bikes use the same plates etc as the kx500.
The biggest problem is you need an extra 10mm of space to fit it in, that's one of the reasons for my custom clutch cover.
Hope this helps?.
Hope to see many pics of this conversion and good luck
Cheers :-)
Dan
cutting torch:
The Z-Start pro is my goal.
The 7/8 scale thing has two parts to it:
1) So many people joke about someone being less of a man if they use an auto clutch, and
2) At 5'4" (162cm) and 140 pounds (62kg), I AM less than your average man, at least in the sence that I take up less space. :-D
torch
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