Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
500AF project
livenlife699:
I did not have to mod mine at all to fit after drilling out the cases..Check the fitment of your spacers that sit in the swingarm, if anything you might have to grind down a mm or 2...Did you use a 43/64" bit or a 17mm?
500donk:
--- Quote from: kxpegger on November 02, 2010, 05:45:35 AM ---Radiator hose rubbing up against the sharp edge coil mount.
Radiator hose rubbing against left radiator tubes.
Left radiator lower tank started to rub against top of frame rail.
Coil lead is pulled very tight and just makes it to the spark plug.
Air box boot flange bolt rubbing on the top of the rear shock gouging about 1/8" of material. Glad I caught that one when I did because it was just about through the shock bladder housing.
Air box boot also rubbing on the top of rear shock and minor rubbing against left frame spar.
Fuel line was to short and kept popping off the carb.
Exhaust silencer rubbing against rear fender.
Kick starter rubs and gouges swingarm/frame engine bolt housing.
Except for the bolded one I considered most of these minor issues and I've found solutions for all of them. Overall SH did a decent job!
--- End quote ---
Kxpegger, how did you fix the problem with the kicker hitting the frame where the swingarm bolt comes through? I?ve gouged the crap out of mine kicking the beast over!
kxpegger:
--- Quote from: 500donk on March 27, 2011, 09:39:30 AM ---
--- Quote from: kxpegger on November 02, 2010, 05:45:35 AM ---Radiator hose rubbing up against the sharp edge coil mount.
Radiator hose rubbing against left radiator tubes.
Left radiator lower tank started to rub against top of frame rail.
Coil lead is pulled very tight and just makes it to the spark plug.
Air box boot flange bolt rubbing on the top of the rear shock gouging about 1/8" of material. Glad I caught that one when I did because it was just about through the shock bladder housing.
Air box boot also rubbing on the top of rear shock and minor rubbing against left frame spar.
Fuel line was to short and kept popping off the carb.
Exhaust silencer rubbing against rear fender.
Kick starter rubs and gouges swingarm/frame engine bolt housing.
Except for the bolded one I considered most of these minor issues and I've found solutions for all of them. Overall SH did a decent job!
--- End quote ---
Kxpegger, how did you fix the problem with the kicker hitting the frame where the swingarm bolt comes through? I?ve gouged the crap out of mine kicking the beast over!
--- End quote ---
Took a Dremel to the frame and removed a slight amount of material. Also from the kickstarter post until it didn't hit anymore. This solved the problem for about a year but as the kickstarter got some slop in it from wear the problem reappeared. It still rubs a little but is "self adjusting" if you know what I mean. I've seen other builds where the offending portion of the frame is completely removed and you might think that it weakens the frame but I have heard of no problems in doing this. I wish I had a better fix. There may be a kickstart lever with a shorter profile at the mounting area that will fit the 500 but I am not aware of one. Wish I had a better answer for you on this one!
500donk:
That was what I was thinking of doing. Thought there maybe some clever stopper that someone had come up with. Thanks Kxpegger.
Just to add to the debate on DNA wheels, I brought a pair on ebay to save some money on the kx500af build and found that they are rubbish. They were about half the price of a set of excel wheels, and while they look sic on the bike, the spoke job is crap and the spacers that I received with the wheels dont fit the front wheel axle tube properly. I?ve changed them around from left to right and vice versa and there is a gap between the outer flanged part of the spacer and the axle tube. It just means with time that the spacer is going to mushroom and create sideways play in the front axle. As with the spoke job, its as if they have not used the correct spokes. On some spokes you can see a lot of thread and on some you can see none. They were loose to. Just not a pro job! Not what you would get with Excel or Talon. I wish I had of read the reviews on them before buying!
don46:
--- Quote from: 500donk on March 28, 2011, 08:58:45 AM ---That was what I was thinking of doing. Thought there maybe some clever stopper that someone had come up with. Thanks Kxpegger.
Just to add to the debate on DNA wheels, I brought a pair on ebay to save some money on the kx500af build and found that they are rubbish. They were about half the price of a set of excel wheels, and while they look sic on the bike, the spoke job is crap and the spacers that I received with the wheels dont fit the front wheel axle tube properly. I?ve changed them around from left to right and vice versa and there is a gap between the outer flanged part of the spacer and the axle tube. It just means with time that the spacer is going to mushroom and create sideways play in the front axle. As with the spoke job, its as if they have not used the correct spokes. On some spokes you can see a lot of thread and on some you can see none. They were loose to. Just not a pro job! Not what you would get with Excel or Talon. I wish I had of read the reviews on them before buying!
--- End quote ---
totally agree with you on the DNA's, guy bragged them up about how big the spokes were and that they were built exactly like a talon and built in the USA. Maybe they were assembled in the USA, but they were surely built in China they are no where near what a Talon is. the big spokes, yeah they are big, but whatever they are made from they are not strong. I wouldn't put them on anything with HP
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