Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
Kx500af almost complete, just need ideas on fixing airbox and rear brake spring
500donk:
--- Quote from: BacK.IN.THE.DaY on January 21, 2011, 04:00:40 AM ---THAT IS A NICE KXAF 500 YOU GOT THERE M8
HOW MUCH HAS IT COST YOU ALTOGETHER
NOT INCLUDING THE ENGINE
I WANTED TO TO THIS WITH MY 87 K5 ENGINE
Yeah its sweet, it just looks mean! Definately worth the effort to build. Its probably cost around $5,000 to $6,000. Not exactly sure. I should have brought a donor Kx450f instead of buying parts individually. Cant wait to ride it. I've never riden a 500 2 banger before.
--- End quote ---
500donk:
--- Quote from: kxpegger on January 21, 2011, 07:32:35 AM ---I think it's Hammerhead the same rear brake lever you have on your bike that offers a kit that deletes the lever to frame return spring and incorporates the return spring on the master cylinder.
Here's the video from Transworld. He's doing the conversion on a Kawasaki so I think it should work on your frame/master cylinder.
http://motocross.transworld.net/1000104024/features/how-to-presented-by-bikebanditcom-shifter-and-brake-pedal-install/
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Thanks mate. I fixed that problem. Just the issue of the airbox now.
speedywent:
99-02 KX 250 airbox boot. It's only $20 or so from kawasaki and you have to make an adapter plate out of sheet metal to make it work but otherwise fits perfect. I used 2 pieces of .063" aluminum and cut them to fit the airbox. I then figured out the orientation of the boot and cut the metal sheets to accept the boot. I used 2 of them to sandwich the boot flange to ensure no leaks and I used lots of sealant to seal the whole setup and it looks great. Toss the backfire screen as you won't need it on the 2 stroke and it makes air filter cleaning much easier. I've heard that the CR250 boot works also but cannot confirm.
Good luck. I see that you still need to secure the pipe to the subframe also. I'll try to get some pics of mine up for you to show you how I did mine.
The brake spring wasn't an issue for me, I only removed the part of the frame as necessary for the kickstarter and the hole for spring attachment was still there.
Enjoy and don't rush it. I sure love mine. I had this one completed and had a 450 as well until the engine grenaded for the last time. It's 2 stroke big bores for me from now on.
500donk:
--- Quote from: speedywent on January 24, 2011, 04:30:53 PM ---99-02 KX 250 airbox boot. It's only $20 or so from kawasaki and you have to make an adapter plate out of sheet metal to make it work but otherwise fits perfect. I used 2 pieces of .063" aluminum and cut them to fit the airbox. I then figured out the orientation of the boot and cut the metal sheets to accept the boot. I used 2 of them to sandwich the boot flange to ensure no leaks and I used lots of sealant to seal the whole setup and it looks great. Toss the backfire screen as you won't need it on the 2 stroke and it makes air filter cleaning much easier. I've heard that the CR250 boot works also but cannot confirm.
Good luck. I see that you still need to secure the pipe to the subframe also. I'll try to get some pics of mine up for you to show you how I did mine.
The brake spring wasn't an issue for me, I only removed the part of the frame as necessary for the kickstarter and the hole for spring attachment was still there.
Enjoy and don't rush it. I sure love mine. I had this one completed and had a 450 as well until the engine grenaded for the last time. It's 2 stroke big bores for me from now on.
--- End quote ---
Thanks for that mate. I'll do that and get a kx250 boot. Sounds like it work well on yours. The bike is going into the shop on monday to get the exhaust mounts welded and have the radiator modified and mounts for the coil put in place. The issue with the rear brake spring was I was to stupid to notice the hole to hold the spring where the swing arm bolt is. I've always owned CR's and wasn't familiar with the Kx.
500donk:
Well I finially finish the mighty Kx500 af and it looks and rides better then I expected. The local motorbike whiz modified and welded up the radiator and the exhaust mounts and it looks as stock as. Fixed the airbox up with the advice of using the Kx250 air boot, and made an alluminium adaptor plate for it to attach to. It was tight but with the aid of some Sika flex it does the job.
I would like to thank everybody at Kxriders.com for there advice and posts. It made things so much easier. I would like to say special thanks to Bempa and his document that he put together on his build. It helped heaps. Here's the pic's!
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