BUILDING A KX500AF with a 2007 KX250F chassis

Bike Builds and rebuilds. Post pics and discuss your projects.
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Sandblaster
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by Sandblaster » Sun May 05, 2013 1:04 am

Thanks to Motorrad I was further examining the fitment between the cylinder and the engine cases.
other concerns.JPG
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Looks like some improvement is required...
Then I checked out this cylinder that was removed from a bottom end on Friday.
Notice the gasket material hanging into the ports?
BAD!
Before my gasket goes on it will be matched.
other concerns 2.JPG
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If bikes are for kids I'll never grow up.

Qsixteen
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by Qsixteen » Sun May 05, 2013 1:50 am

Rick Peterson dyno testing a base gasket that hang into the transfer .250" and it didn't change the dyno numbers. Just like a mismatch at exhaust outlet and header flange.

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Sandblaster
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by Sandblaster » Sun May 05, 2013 1:59 am

Interesting.
I wouldn't do it on my build.
What do you do on yours?
I really like this article:

http://www.hallbergs.net/kx500/

I have seen it referenced many times in the past few years but I finally sat down and read it.
Here's some pics of their port work.
port 1.png
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port 2.png
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port 3.png
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If bikes are for kids I'll never grow up.

Qsixteen
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by Qsixteen » Sun May 05, 2013 2:11 am

It doesn't hurt to trim them up. On my devcon motor I have to make a base gasket.

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Sandblaster
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by Sandblaster » Tue Oct 15, 2013 9:42 pm

Made a trip to the welders last week and got all the mounts welded up.
You can remove and install the engine if you remove the gas tank.
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If bikes are for kids I'll never grow up.

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Sandblaster
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by Sandblaster » Wed Nov 20, 2013 1:56 am

I finally spent some time on this project today.
I made another version of the two piece clutch cover to keep the cost as low as possible.
I think 5 profiles and all the holes can be machined in one set up, then the last step would have to be done one at a time unless a jig was made.
But for now, no jig..
I'm getting quotes on the material and the machining.
I hope to have some news fairly soon.
After a few of us verify the design viability then I will let every one know the cost.
Then, I will look at making custom covers and a slightly different design :-o
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by Sandblaster » Wed Nov 27, 2013 9:11 pm

Here is the next challenge..
The gas tank hits the head even without the petcock valve.
As shown earlier, I destroyed my last tank so I will be a bit more careful when molding this one ;)
GAS TANK INTERFERANCE.JPG
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Using a Petcock valve and remote reservoir from a KLX450 will help the problem but it is not a cure all...
pet cock comparison.JPG
pet cock comparison.JPG (78.08 KiB) Viewed 3305 times
Since I burned a hole in mine using a heat gun last time I am going try boiling my next one.
If bikes are for kids I'll never grow up.

500heaven
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by 500heaven » Mon Mar 30, 2015 12:28 am

What pipe did you use for this bike i talk to service honda they dont know whats the best pipe for that built i saw that you use a fmf pipe what year and what model is it from?

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Sandblaster
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by Sandblaster » Mon Mar 30, 2015 9:02 pm

I used the Service Kawasaki pipe.
It took a little phone work and convincing to get them to sell it to me.
They said the reason for them not wanting to sell it is because these are a custom fit.
So, you may need to make some new brackets and wiggle it around.
In truth, mine fit really nice and I had to make custom brackets anyway.
If they will not sell you one then you can get the use the head section from a KX500 pipe and weld it to the rear section of the CR500 pipe which is what Service Kawasaki does :D
If bikes are for kids I'll never grow up.

africanfish
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Re: BUILDING A KX500AF with a 2007 KX250F chassis

Post by africanfish » Tue Mar 29, 2016 6:13 pm

Sandblaster wrote:I had considered a slightly different design but decided in favor of the design above:
mount.JPG
Is there some way I can get this diagram to print out and use to trace it on the metal to cut it with a plasma cutter and it be the n the correct size? This is for the front engin mount using the head bolts.

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