Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
HELP w assembly
81cr450:
I'd really like to show some riding pics as I live in 500 land. My wheels also arent trick just an 84 yz490 rear rim & a 89 cr 500 front. The 84 yz rear rim is 32 spoke & 2 1/2 inch, I shouldnt share that but O well. I also got rid of the cheasy plastic cased clutch shaft bearing with a factory honda steel cased bearing, & I'm trying a half sealled bearing on the sprocket side of the case to try to help keep out debris, I popped the seal out of the trans side & left the seal in the counter shaft seal side
454SS:
Is that a gen2 frame? Even so, I'm surprised the kx motor fits so closely. Should be a nice handler. Good luck! (Good you didn't convert the old alu frame)
81cr450:
Yeah its a 2001 gen2. The k5 case is like an inch shorter than the CR5, which is part of what makes this do-able. You also get alot better power too :mrgreen:
Just a couple pics here to show what I mean by flat spring to clear the frame. It still needs to be cut to length but it makes a clearer illustration.
Theres a pic to show how close it gets to the frame on the powervalve access, also it shows how I made the spring hook eyes into spring hook ears. I grooved the back side of the ears with a dremel to keep the spring from sliding off.
The tail of the pipe need a little bend & the arrow it pointing at the joint that needed bending the arrow is also pointing the dirrection I had to bend it.
The kicker pics illustrate yet again one of the poorest parts of an af build with the k5 motor. It needs more of a cr500 bend like they did with the advancement of the lowpipe in 1989 , the k5 stuck with the high pipe clear through 2004 so the kicker is just not ideal. I'm gonna use an old forged steel kdx420 kicker & hopefully I can bend it to fit without weakening it to the point I end up with it sticking through my calf muscle.
Also notice the fliped water outlet, pretty standard AF fare.
Mod's sorry for all the pics, if its a waste of space feel free to delete or edit as you see fit
454SS:
That's a tight fit! The honda guys will go as far as clearancing the 'Y' by grinding some alu out of the crotch of the 'Y'. Some of the stuff they do to make the motor fit seems scary but who knows.
I thought that was a pic of your hand and thought, cool, the guy's missing fingers and can still fab the bike. Then i noticed it's one of those Dr Evil pets! :-D
81cr450:
No I'm "barely" skilled enough to fab with all my fingers, not like the awesome Dude with no arms who can change his own brakes.
Her name's Peaches & she is a whole lotta help. Hard not to get a pic of anything around here without a couple sphynx investigating what your doing. I had to hide my new tall seat cause they thought it was for them to sharpen their claws on :evil: little demons
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