KX Riders

Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: bempa on March 25, 2009, 10:07:24 AM

Title: KX500AF 2007 Build complete documentation
Post by: bempa on March 25, 2009, 10:07:24 AM: Here is what came out of my KX500AF build besides the actual bike.
The documentation contains tips and how to's and lot's of pictures.
Title: Re: KX500AF 2007 Build complete documentation
Post by: jfabmotorsports.com on March 25, 2009, 10:29:47 AM: Very nice write up. Your bike came out great. Also, thanks for acknowledging all the people that gave you inspiration and help. Most people that I run into are members of the "I DID IT CLUB". Class act...Let us know how it rides!

JFAB
Title: Re: KX500AF 2007 Build complete documentation
Post by: kxpegger on March 25, 2009, 12:02:06 PM: Outstanding!
Title: Re: KX500AF 2007 Build complete documentation
Post by: smrtguy212000 on March 25, 2009, 12:42:51 PM: Well done sir! Great reading.............I just got the "evil eye" from my wife. She knows...
Title: Re: KX500AF 2007 Build complete documentation
Post by: Good on March 26, 2009, 05:42:16 AM: Yeah, great job! 8-)
Title: Re: KX500AF 2007 Build complete documentation
Post by: stewart on March 26, 2009, 02:25:39 PM: cool write up,,,that guy in the piston mod picture needs to clean his finger nails
Title: Re: KX500AF 2007 Build complete documentation
Post by: Reddy on March 27, 2009, 01:48:19 AM: Thats a real good read! Bike looks awesome.

Out of interest will the CR airbox boot fit a KX250 conversion? Its the last problem i have to sort.
Title: Re: KX500AF 2007 Build complete documentation
Post by: bempa on March 27, 2009, 02:27:43 AM: The use of a CR250 airbox boot applies to KX450F 2006-2008 frame.
Are you building a KX250AF or a KX500ST (steel frame) ?
Title: Re: KX500AF 2007 Build complete documentation
Post by: Danger4u2 on March 27, 2009, 03:00:42 AM: Your write up looks like it came from a New York ad agency. I'm impressed with it and the final product.
Title: Re: KX500AF 2007 Build complete documentation
Post by: AJ on March 27, 2009, 08:57:44 AM: very nice!
Title: Re: KX500AF 2007 Build complete documentation
Post by: Reddy on March 27, 2009, 09:34:12 AM: Quote from: bempa on March 27, 2009, 02:27:43 AM
The use of a CR250 airbox boot applies to KX450F 2006-2008 frame.
Are you building a KX250AF or a KX500ST (steel frame) ?
I'm building a KX250AF, I bought a KX250 boot but it wouldnt go between the frame and the shock.
Title: Re: KX500AF 2007 Build complete documentation
Post by: speedywent on March 28, 2009, 07:37:29 PM: I am in the process of building my 2006 450F/500AF. As soon as I get my cylinder work done this week I will be doing the frame mods to complete the job. I have a couple of questions that I was hoping that some of you could help me with.

I was wondering if the coolant hose that goes from the bottom end to the top end on the right side works or is it necessary to re-route like the Service Kawasaki one is? I am using a service FMF Gnarly.

Does the radiator (specifically right side) clear the frame when the "Y" is raised?

Can the hoses be routed to use on the radiators as-is without radiator modification? I have spare radiators and if I damage one I don't want to have to custom make them everytime I need one.

I welcome as many pictures of anyones build. Any information on obstacles encountered and resolutions to these obstacles. Thanks in advance
Title: Re: KX500AF 2007 Build complete documentation
Post by: edgar_kx3 on March 29, 2009, 02:49:44 AM: reddy i had the same problem with the boot the kx 250 boot would not go!! i used the stock 250f boot and made a coupling to size it to fit the kx carb
<a href="http://viewmorepics.myspace.com/index.cfm?fuseaction=viewImage&friendID=33575869&albumID=2669444&imageID=57400706"><img src="http://hotlink.myspacecdn.com/images02/86/753203ad790545a89b13f278979daee5/m.jpg" alt="" /></a>
Title: Re: KX500AF 2007 Build complete documentation
Post by: bempa on March 29, 2009, 08:23:57 AM: Speedywent,
As you can see on the pictures, the left side lower radiator mount is a close call after the frame cut.
The right side is fine and does not need any removal/rewelding of the lower mount.
Title: Re: KX500AF 2007 Build complete documentation
Post by: doordie on March 30, 2009, 07:37:52 AM: You don?t leave any questions unsolved Bempa,this is a masterpiece of documentation how to building a AF. 8-)
This is good for me too,very easy for you to build mine AF soon! :-D
Title: Re: KX500AF 2007 Build complete documentation
Post by: jrhockey03 on March 30, 2009, 08:01:33 AM: Hell of a how to, and in a convenient PDF. Now all I need is a rolling chassis and 500 motor. haha I'll have to sell my little KX250.
Title: Re: KX500AF 2007 Build complete documentation
Post by: Reddy on March 31, 2009, 08:43:13 AM: Quote from: edgar_kx3 on March 29, 2009, 02:49:44 AM
reddy i had the same problem with the boot the kx 250 boot would not go!! i used the stock 250f boot and made a coupling to size it to fit the kx carb
<a href="http://viewmorepics.myspace.com/index.cfm?fuseaction=viewImage&friendID=33575869&albumID=2669444&imageID=57400706"><img src="http://hotlink.myspacecdn.com/images02/86/753203ad790545a89b13f278979daee5/m.jpg" alt="" /></a>

Yeah looks good, shame I cut mine into pieces to try and make an adapter!
Title: Re: KX500AF 2007 Build complete documentation
Post by: bempa on April 07, 2009, 09:09:13 AM: To eager, to soon, to much snow. Had to leave the bike and get some help.