KX Riders
Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: stevea100m on January 02, 2011, 03:48:57 AM
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So i started my build last night of my KX250f with an 03 KX250 motor. I got the cradle cut and the yoke piece trimmed and ready to see how it fits. Now I'm going to take the motor out of the KX250 and put it in too see if I need to take more off of the down tube to the cradle.
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sweeeeeet!!
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Very nice!
I have not cut my frame yet, but I will shortly...
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Okay so i spent quite a bit of time working on the yoke today, about a good 4 hours. I did at least get a front end on the bike and need to get the motor out of the donor 250 to make sure it all fits right. The front end that's on it right now wont be the exact one as it is for another bike and im waiting for my forks and triple clamps to get here.
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Nice progress.
I can't wait to see how it turns out.
I have to get movin on mine....
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I'm trying to be meticulous about a lot of it as i want this thing to make jaws drop when I'm at the track
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I was going to slap mine together just to see how I like it.
But, one thing led to another and I'm going full tilt.
Oh well, it's only time and money :cry:
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Yea thats true but might as well do it right the first time
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That old adage continues to haunt me....... :lol:
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So i had an iteresting side note happen to me before i started workin on the bike today. I had this build also posted on dirtrider.net and the site moderator deleted it, calling me a hack and telling me i could not call my bike an AF because it is a trademark of service honda.
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stick with this site its the best, you could call it a kx250FA, FA standing for frame aluminium or f@#% awf lol
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So i had an iteresting side note happen to me before i started workin on the bike today. I had this build also posted on dirtrider.net and the site moderator deleted it, calling me a hack and telling me i could not call my bike an AF because it is a trademark of service honda.
It probably is a trade mark, but for a site moderator to call you a hack? :?
It's amazing to me what some people will say when they don't have to look another person in the eye. :x
It's like I said on another forum, instead of belittling, why not educate?
I do not go to any other forums for info.
Since finding this site.... why bother? :-o
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You can't use KX either! That's a trademark of Kawasaki. Engine displacement using numerals may also be taken and off limits. Would like to offer at this time a trademark neutral nomenclature for a small fee and you can keep the trademark!
G2FNFF which stands for Green2FiddyNonFerrousFrame. What do you think?
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Well I emailed AJ back and forth a couple of times today and he said I can call it an AF if i so choose but if I were to sell it that it could not be represented as an AF. As far as the build goes I havent got much more done just spent time cleanin the garage so i could build one as I tear the otherone down
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im workin on mine now too, i got almost all the parts i need, i just gota cut the cradle out and fire up the welder
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Got the motor out of its old home and into its new one today. gotta do a little adjusting at the yoke area but now im waiting for my swingarm to show up so i know its centered. Once thats done I can get the rails from jfab and send the frame to the welder. Once the frames welded I'm going to rebuild the motor so I have a new motor in my new bike.
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Your making great progress.
I'm waiting for my rails before I can do much more.
Hurry Jerry, hurry... :-D
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Im ordering my rails today hopefully caus im pretty much to that point
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It may take Jerry a few days to get back to you but don't worry, he will :-)
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Well I got the shock linkage today so i can make sure the pipe is going to clear the shock but I'm still waiting for the swingarm to show up. It kinda sucks too as I have to go back up to college since school is starting next Monday. In the long run though it just means that I can get more stuff done on the weekends.
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Well i cut about 1/4" more off the down tube and got alot more room near the cylinder head. Got the linkage on also today. Now im just waiting for the swing arm so i can center the motor left to right.
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Okay guys since i got back this weekend I got quite a bit done. The swing arm and swing arm blot showed up but still no subframe so that pisses me off a little. I got the swing arm bolted up to the frame and checked the chain alignment to make sure all was square before made the measurements for the spacers in between the motor and the swing arm as the motor is skinnier than the swingarm opening. I still have not heard from Jfab as far as ordering some rails but once i get the rails it can go off to the welder to start making motor mounts and get this bike read for the track
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I just went through the swing arm fiasco, you might want to check out what I did:
http://www.kxriders.com/forums/index.php/topic,8351.0.html (http://www.kxriders.com/forums/index.php/topic,8351.0.html)
Measurements will vary so don't trust mine :-D
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Well didnt have any parts to work on my bike this weekend but I got the airbox gas tank and rear shock on the way. I am still waiting to hear from jerry on getting a set of rails. In the mean time i can get my airbox boot adapter plate made and get the motor mounts made so when the rails get here i can have those welded in at the same time.
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I got my rails from Jerry and they look marvelous!
I've been too busy with my shop but I'll toy with it this week :-D
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Well the subframe finally showed up today. After buying one on ebay and then having to draw a case against the seller and buying a different one, I finally got the subframe I needed. I only need to get a few more parts like the front and rear wheels, front suspension and radiators. I plan to put some seriouse time in on it this weekend to hope fully finish the motor fitment and then send it to the welder.
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Can't wait to see it. :-)
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nice job.....
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hi mate ,im doing similar 2008 kxf250 frame ,jan de groot kx250 grand prix engine if i remember correctly sprocket side spacer 9mm kickstart side 8mm i used a 17mm drill on the lathe and turned them down to 28mm used the old chain buffer on the swing arm for reference but will ping a lazer down the centre line before i weld it up ,i will check tommorow on the spacers with a vernier and let you know ! not sure what im going to do about the LH rad mount very tight to say the least on the rad , prob cut off and reweld on . ground the old tube out of the cast part of the frame still had to file down after the die grinder , jerrys rails fit atreat just got to trim down for lenth. ta jerry
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Well I got the subframe and airbox in this weekend just to see how everything fits as of now. I ordered the 00 honda 250 airboot, it should be here this week along with my radiators, front forks and hopefully if i get ahold of jerry tomorrow then maybe my frame rails will be here by friday.
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So I spent the better part of a day and a half workin on the adapter plate for the airbox to put the cr250 air boot on and once I got done with it and got it mounted up i just have to get a reed space. The only thing im tryin to figure out is weather I want to put it in between the cylinder and reeds or the intake and the reeds. I also got a set of oversized cr250 radiators for the bike and now have to move the lower water spicket on the right radiator out about an inch or so. I have all the plastic on the way for it so it should look like a bike by the end of the week.
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SO i got a little work done this weekend. I worked on gettin the radiator brackets made for the oversized 02 CR250 radiators. I also figured out how im going to run the radiator hoses for the bike. I have to have the right side lower radiator spicket moved outward as it hits the cylinder. I got my new plastic in so i just had to put it on to see how it looks. Gonna get the now rod and piston ordered friday. Figure if I'm building a new bike might as well have a new motor
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So i changed how most have mounted the radiators. I decided to make an adapter bracket to make them fit easier. I havent finished them yet as i have to weld two spacers on each bracket and once i get that all done then im going to trim the excess material away so they dont catch anything
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So I finally got my over sized tank I was hopin to get. Its an IMS 2.8 gallon tank. It has a lot more clearance for the spark plug than the stock tank. Im taking it all apart this weekend to take it to the welder. I probably wont finish it till the middle of may as Im headed to Vegas for the supercross finale.
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Gettin some real work done today! I bent up a set of frame rails and started fitting them to the frame so far Ive got one done and am going to start doin the other side after a short break
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I really like the radiator adaptor plate idea! I never thought about that! I just cut the lower mounts out of my 500SF project and welded them forward slightly. It would have been a ton easier and nicer looking to make the bracket. Oh well Ill remember it next time.
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Gettin some real work done today! I bent up a set of frame rails and started fitting them to the frame so far Ive got one done and am going to start doin the other side after a short break
Do yo still have the steel roller? If you do, are you willing to sell it as a whole roller?, and how much$?
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Where do I begin, its been a while since I posted an update on the bike. Since my last update I completely changed which radiators I used, I decided to go with radiators off of a 2002 kx250 and just have the tanks modified to clear the frame. obviously the radiators have the to crossover pipes on them so i had to figure out what to do there. So I got on the summit racing website and found weld on threaded bungs and some -an fittings that thread on and come straight out of the radiator and turn to a 90 degree angle and they work really well. I also have since the last update made the motor mounts and had the whole frame welded by a very reputable welder that has welded some AF conversions before. THe bike is fully assembled and I am just waiting on a petcock so I can hear this thing run. I still need to heat the bottom of the tank to clear the shorty spark plug that is in the motor. One thing I had to also do was use the hammer head designs brake clevis kit as the pin was missing for the pedal and i couldnt get the spring hooked to the pedal as the motor was in the way. I highly recommended this as you can also adjust the pedal tension. Here are some pics of the stuff that I have done if anybody wants more specific pics let me know
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-26_17-55-43_813.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-27_17-15-06_850.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-27_17-15-13_304.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-27_17-15-19_85.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-27_17-15-26_498.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/1315957517777.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/1315957524114.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-29_17-47-48_812.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-29_17-46-19_416.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-29_17-46-12_546.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-28_18-54-42_961.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/rearbrakeclevis.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/newhandgaurds.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2011-12-29_18-41-32_802.jpg)
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bit late i guess but i used kx125 rads fit straight on no mods required ,again bit late but if you need any info check out my post jan de groot etc
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I had seen your when I was looking at moding a set of radiators but this was the easiest as I already had the radiators and made the block off plates myself, so just cost effective on my side. But if I smash one I may try that next
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Looking good!
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I'm trying to be meticulous about a lot of it as i want this thing to make jaws drop when I'm at the track
like this one?
(http://i83.photobucket.com/albums/j283/HOGIE888/KXrebuild109.jpg)
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IT LIVES!!!!!! I had it running last night on the stand and all I can say is I cant wait to ride this thing. I just got some tall stiff seat foam installed today as well, and what a difference it makes for a taller rider.
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No pictures... it never happened! :roll:
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Im hoping to have a video up this weekend
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Got the graphics on it the other day and as of last night it doesnt look like a bike again cause i had to take the suspension out but heres what it looked like before
(http://i668.photobucket.com/albums/vv45/stevea100l/2012-02-20_15-58-42_421.jpg)
(http://i668.photobucket.com/albums/vv45/stevea100l/2012-02-20_15-58-51_661.jpg)
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Lookin sweet!
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Nice bike. When i had a kx250 03, we would use a 1mm washer in the exhaust advancer inside the clutch cover and a pro curcuit pipe to get more top end, as well you can get a porting map and other mods off the team green site. kx250f handle better with 22mm offset triple clamps.
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Well I finally got to ride it and it is probably the best bike I have ever ridden as far as handling and ergonomics for a tall guy goes. I took it to the track along with my 03 kx125 for back up in case something hindered me from riding the AF the rest of the day. I rode my 125 the first 3 laps then it was time to try it out. I had to adjust the brake pedal and the levers and small stuff after a few laps but after that I didnt get off the thing! I absolutly love this bike. Here is a picture of what it looks like and I am working on posting a helmet cam video of it this afternoon. Thanks for all the help and support on this fellas, and I think a 500 AF is in the future works
(http://i668.photobucket.com/albums/vv45/stevea100l/firstrideAF.jpg)
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heres the video fellas http://youtu.be/mYfNv6saQJ4
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Congrats on your build! That bike will always be special because you hand (grafted) it! Turned out nice!
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Thanks! I've gotten alot of compliments so far on it and im sure once racing season starts it will be the talk of the track
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Very nice!
It gives me the itch to get mine going.
Building my shop has hindered the progress on my build but some things will be starting to happen soon.
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It was definitely a fun bike to build and I definitely learned alot and plan to build at least 1 500 and maybe if my old man like my bike we maybe converting his 06 kx250
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Great build mate, these af builds are sweet :mrgreen:
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yes they are and I may be building another one for my brother after me and him raced a team event on it this last weekend. He compared it to throwing a 125 around in the air
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Got back on the AF for the first time in a month yesterday as the stator went bad so I had to track down a new one. I had been riding my 03 kx125 and jumpin back on that 250 I forgot how much fun that bike is. I do need to figure out how to make it so it doesnt wheelie as much though. I thought about chnaging the gearing but I'm already running a 14/48
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Consider using a 450 swingarm, it is a bit longer
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roughly how much longer?
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don't remember exactly, it isn't huge maybe an inch ish, of course that is huge when it comes to wheelieing
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Well I raced the jackpine enduro on it this last weekend and AJ at service honda told me that when I got it into the tight woods I would love it and he was right. Made my day effortless compared to the steel frame. Had alot of people askin about it and one thing I can tell is people just dont understand why we build these fun bikes
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Wish the pics would come up Im getting ready to start mine!