Maintenance & Technical > KX500 Steel Frame Conversion (SFC)

KX500PF

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cutting torch:
I talked to JFab, and he is taking care of me. We are going to do some collaboration on a headstay that will work for my combo, and hopefully for many others.

Stay tuned, but be patient. I have an out-of-state business trip, and an out-of-state riding trip in the next three weeks.

torch

cutting torch:
Now for the cooling of the beast.....

The 500 has a series cooling circuit, and the 250 is a parallel cooling circuit. I need to use the 250 system since it fits the chassis (just like stock!:busted:). I'll describe how each system flows, starting at the water pump inlet.

500:

Water pump inlet, to wp outlet, to right side of jug, up through jug to head, out of head on the left side, to bottom of left rad, from top of left rad to top of right rad, from bottom of right rad back to the water pump inlet. This circuit is in series since the coolant flows through one radiator, then flows through the other.

250:

Water pump inlet, to wp outlet, to rear side of jug, up through jug to head, out of head on the top rear WITH TWO OUTLETS going to the top of each rad, through both rads to the bottom of both rads, and back to the water pump inlet. This is parallel since the coolant flows through both radiators at the same time.

Just in case anyone thinks I am belittling them by spelling out the differences between series and parallel, remember that there are some people that just never knew this. It's for thier benefit. So :p.

Next post has pics!

torch

cutting torch:
Pics! Whoooo!

The water pump inlet manifold from the 250 is wider than the 500, from bolt-to-bolt....



So, I welded up the holes to relocate them:



Then, I milled and drilled: Note: KX500 heads seem to be a purer alloy than KX250 water manifolds, based on the way they weld. I need to fix these pits:



In order to move the bolt holes in, I needed a smaller bolt head. Hello, Allen!



The factory bolt was too fat:



Here are pics of how things will lay out. I still need to make a wye to split the coolant between the radiators for the parallel arrangement I want. That wye will split the coolant flow in half between the head and the top of each radiator.







torch

ZETTNORCAL:
SWEET!! :-o

Goat:
Excellent work. Looking good.

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