Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
HELP w assembly
81cr450:
I ended up doing more powdercoating than anything last weekend. I did manage to get the new rear pipe mount made & tacked on as well as the head pipe tacked too. Another demonstration of tac first, fit, then cut off, re-tac, refit. Just glad it wasnt more than a tac as the rear mount needs to be clocked a little. All in all happy as the spring clears the frame good
81cr450:
Got a pic or 2, can you tell whats missing. Been 6 1/2 months waiting on a recoat and head cut & some parts. SICK of waiting when thats the first stuff I sent out. But I did get back a "nice" case. I added some jb weld thinking it might strengthen & dampen the side of the crank that shows the most bearing wear on the cases & crank. I also got the measurments doing the 3rd case cut & the swinger bolt size. I used a .658 drill bit for the hole & then hone it with a sunnen rod hone to get a final size of .665 on the rear swinger bolt. I've heard you can kill alot of af vibes here by keeping the size tight. the final width of the case comes in at 3.320 with .255 coming off the sprocket side & .115 coming off the clutch side. I will epoxy the dead space in the rear of the case to help strengthen it as well as prevent leaks. I didnt go through on either case so it should still be quite solid so no worries on the case in the rear, but if your anal you can epoxy in extra material like an old wrist pin for more support. Thats what I did on the first bike but I really think its okay without. I'd also like to add I'm a sucky welder, but the pipe does fit & I'll have more pics of it when I have a motor.
81cr450:
This is my broke time of year & I got held up with the motor over the summer, so put me on the fast track to a slow build. :-D I did end up with a 90mm bore cylinder back from the motor mess, but no head so I have a hang up there. I did come up with a cherry 2004 std cylinder in the meantime though. What I'd like some input on is, are 90mm bores bad, or should I send off my std bore jug & just replate it. Some of the guys I've talked to think the 90mm might be :roll: questionable. Im sure I could sell it & get my stock jug plated, I'm just curious if its a bad call or should I use it. Either way I'm still short a head but I'm kinda wondering which jug to get rid of. I also have a sleeved 87.5mm jug with a good used 88mm piston I could use too,525 :evil:, but I wanna stick with the nikasil for longevity.
As the title states HELP
Motorrad:
--- Quote from: 81cr450 on October 25, 2011, 01:18:54 PM ---This is my broke time of year & I got held up with the motor over the summer, so put me on the fast track to a slow build. :-D I did end up with a 90mm bore cylinder back from the motor mess, but no head so I have a hang up there. I did come up with a cherry 2004 std cylinder in the meantime though. What I'd like some input on is, are 90mm bores bad, or should I send off my std bore jug & just replate it. Some of the guys I've talked to think the 90mm might be :roll: questionable. Im sure I could sell it & get my stock jug plated, I'm just curious if its a bad call or should I use it. Either way I'm still short a head but I'm kinda wondering which jug to get rid of. I also have a sleeved 87.5mm jug with a good used 88mm piston I could use too,525 :evil:, but I wanna stick with the nikasil for longevity.
As the title states HELP
--- End quote ---
what reasons are they giving for the 90 being questionable..
(besides the thing I know is wrong with your cyl... that was supposed to get fixed, and didnt)
DoldGuy:
--- Quote from: 81cr450 on October 25, 2011, 01:18:54 PM ---This is my broke time of year & I got held up with the motor over the summer, so put me on the fast track to a slow build. :-D I did end up with a 90mm bore cylinder back from the motor mess, but no head so I have a hang up there. I did come up with a cherry 2004 std cylinder in the meantime though. What I'd like some input on is, are 90mm bores bad, or should I send off my std bore jug & just replate it. Some of the guys I've talked to think the 90mm might be :roll: questionable. Im sure I could sell it & get my stock jug plated, I'm just curious if its a bad call or should I use it. Either way I'm still short a head but I'm kinda wondering which jug to get rid of. I also have a sleeved 87.5mm jug with a good used 88mm piston I could use too,525 :evil:, but I wanna stick with the nikasil for longevity.
As the title states HELP
--- End quote ---
I have seen a few of the "Big Bores" lately needing lots of Head Gasket attention. On that big of a bore you are getting very close to the head studs & water jackets with the bore, but with that said, these motors I have seen are running very high compression which I am sure is not helping matters. I will wait to see if there is a cure.
Hope this helps,
DoldGuy
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