KX Riders

Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: edgar_kx3 on April 03, 2009, 01:48:58 PM

Title: Another Project!!
Post by: edgar_kx3 on April 03, 2009, 01:48:58 PM
Came up with a few parts off a 06 KX450, frame swingarm, linkage and shock, and found me a 89 kx500 with a good motor today going to combine them!!! Anybody have any pointers??
Title: Re: Another Project!!
Post by: jfabmotorsports.com on April 03, 2009, 02:38:18 PM
Contact me for any question that you might have. I will gladly answer your questions.  jerrysfab@centurytel.net

JFAB
Title: Re: Another Project!!
Post by: The Flyin Hawaiian on April 04, 2009, 09:23:45 AM
jfab, have you done any 03/04 KX250 steel frame conversion? Im so close to doing it, my 04 250 suffered some engine damage last weekend and I have my 02 500 engine almost ready to pull out tonight.
Title: Re: Another Project!!
Post by: jfabmotorsports.com on April 04, 2009, 01:21:29 PM
TFH....You have been PM'ed
Title: Re: Another Project!!
Post by: speedywent on April 04, 2009, 04:13:10 PM
Jfab, I'm putting together a 2006 kx450f and 1992 kx500 engine, if you have pics of previous jobs they would be appreciated. That way if I run into unforeseen obstacles I can refer to your blueprint. Thanks in advance.

DW
Title: Re: Another Project!!
Post by: bempa on April 05, 2009, 10:57:11 PM
Speedywent, see my documentation. Could be useful for your project.
    
Forum subject:
KX500AF 2007 Build complete documentation
Title: Re: Another Project!!
Post by: edgar_kx3 on April 07, 2009, 05:29:39 AM
workin on my 500 engine!!! any advice on the kips, any adjustments or tips?
Title: Re: Another Project!!
Post by: bempa on April 07, 2009, 09:03:35 AM
http://www.hallbergs.net/kx500/
Title: Re: Another Project!!
Post by: speedywent on April 08, 2009, 05:17:32 AM
Yeah that's great illustration and instruction. All is appreciated. I was just looking for additional pictures. Kawasaki shows the 2006, 2007, and 2008 to be different PN's but they all look the same to me. I have a 2006 and 2008 cannot see any differences. Oh well, here goes the cutting.
Title: Re: Another Project!!
Post by: edgar_kx3 on April 12, 2009, 12:00:29 PM
alright, well i have torn down my 500 engine and everything is perfect, oh and also she has been sleeved 80 over, no wonder it was so fast!!! but anyway im going to put it back together next week and the kip valve timing marks are worn off the valves!!! so hows the best way to get it in time without the marks???
Title: Re: Another Project!!
Post by: doordie on April 15, 2009, 12:08:22 PM
alright, well i have torn down my 500 engine and everything is perfect, oh and also she has been sleeved 80 over, no wonder it was so fast!!! but anyway im going to put it back together next week and the kip valve timing marks are worn off the valves!!! so hows the best way to get it in time without the marks???

Pull pullrod as far out it goes and then put in geared Kips-drums in place and then third gear in....check it closes
and open right.
Title: Re: Another Project!!
Post by: jfabmotorsports.com on April 15, 2009, 03:37:58 PM
speedywent, Did you get the email with the zip file of pics?

JFAB
Title: Re: Another Project!!
Post by: speedywent on April 16, 2009, 12:01:47 AM
No, I did not. Can you try it again? I have all of my frame fittings cut off and my welder and I are going to do the frame mods not this sunday but the next sunday 4/26 (he has a busy schedule). Pics would be appreciated. Thanks again. SpeedDemon@charter.net

DW
Title: Re: Another Project!!
Post by: edgar_kx3 on April 16, 2009, 11:07:10 AM
i wonder, can i order a pipe for my kx500af from service honda??
Title: Re: Another Project!!
Post by: speedywent on April 16, 2009, 06:06:02 PM
Yes, I ordered my Gnarly pipe and silencer from AJ but haven't installed yet. I have to finish my frame mods first. Here is the link to the post.

http://www.kxriders.com/forums/index.php/topic,4721.0.html
Title: Re: Another Project!!
Post by: edgar_kx3 on April 21, 2009, 11:04:24 AM
Now i can POST my pics :-D!!!
Title: Re: Another Project!!
Post by: edgar_kx3 on April 29, 2009, 12:12:26 PM
UPDATE!!!! i started on my 500af this evening, have the engine in the frame. I cut out the old motor mounts, and the down tube, going to start building my mounts tomarrow!!! will keep you all updated, i will try to have pics up tomarrow!!!
Title: Re: Another Project!!
Post by: edgar_kx3 on May 01, 2009, 01:18:10 PM
The project is started
Title: Re: Another Project!!
Post by: edgar_kx3 on May 10, 2009, 10:48:26 AM
My 500af, fitting the service honda exhaust to my chassis!!!!
Title: Re: Another Project!!
Post by: kxpegger on May 10, 2009, 10:59:06 AM
Looking good! Invert your cylinder hose connection and get the 180 degree Service Honda radiator hose too! Gives you all the clearance you need next to the pipe.

(http://i155.photobucket.com/albums/s301/peteegger/Wicked500ccofKawai006.jpg)
Title: Re: Another Project!!
Post by: edgar_kx3 on May 10, 2009, 12:57:09 PM
how much does the hose kit cost??? also i have a problem with my kickstart, it bottoms out on the frame before it gets the the peg!! how is the fix, do you have to space the kickstart out or what???
Title: Re: Another Project!!
Post by: jfabmotorsports.com on May 10, 2009, 01:07:45 PM
The fix! 

JFAB
Title: Re: Another Project!!
Post by: kxpegger on May 10, 2009, 01:30:06 PM
how much does the hose kit cost??? also i have a problem with my kickstart, it bottoms out on the frame before it gets the the peg!! how is the fix, do you have to space the kickstart out or what???
Mine did that too from Service Honda. About 60 thousandths with a Dremel took care of the problem. JFab's picture shows much more removed but whatever works. Every frame and motor combo is going to be slightly different with different requirements for clearances.
Title: Re: Another Project!!
Post by: edgar_kx3 on May 10, 2009, 01:39:04 PM
very NICE!! thanks for the advice , that was the route i was guessing but wasnt sure..get mine fixed up tomarrow, going to get everything welded next week, will get some pics up when i get it done!!
Title: Re: Another Project!!
Post by: The Flyin Hawaiian on May 10, 2009, 04:14:44 PM
Would anybody happen to have a picture of the airbox boot to airbox mounting? I did mine last night and would like to see how everyone else did theirs.
Title: Re: Another Project!!
Post by: edgar_kx3 on May 18, 2009, 05:45:38 AM
AJ if you are out there how do i get the service radiator hoses for my kx500af???
Title: Re: Another Project!!
Post by: elemeno187 on June 29, 2010, 12:24:34 AM
Bad machines here!!!
Title: Re: Another Project!!
Post by: patz on September 24, 2010, 03:52:39 AM
Edgar:

I'm interested in purchasing your KX500 rolling chassis.  Any interest in selling it?  Where are you located?

pat
Title: Re: Another Project!!
Post by: edgar_kx3 on September 29, 2010, 12:37:52 AM
sorry pat already sold it. i do have a cr500af on ebay right now if you are interested!
Title: Re: Another Project!!
Post by: patz on September 29, 2010, 02:18:23 AM
Thank you anyway.  I'm putting together an F450 moto style kx500 roadracer.  I already have my motor ( i initially tried to put it into a TZ250 chassis) and need some chassis pieces.