Posts
11
Joined
6/7/2014
Location
NL
Edited Date/Time
10/17/2015 10:45am
Hello,
Last months I've been working on a project for myself, a KX500AF conversion with a '91 engine and a '09 KXF250 chassis. My project is finished now, and I like to share my work with you.
Starting with the 1991 engine:
The 2009 KXF250 rolling chassis:
I want to make the clutch cover divisible, so I cut the carter in pieces:
Developing an answer with SolidWorks to this problem:
Developing a new chain protector:
Developing a new Y part (red parts into existing frame):
Starting cut the frame down:
Making myself some new pieces with a waterjet cutter:
Making the clutch cover:
Making the chain protector:
Insert the Ypart:
Building a new brake pedal:
Making a adaptor for holding the head of the cilinder:
Cut new radiators completely down, and built some new one (I used two new right KXF250 radiators because of the available space):
Bought new pegs, and new Factory wheels:
Making the subframe fit a new Pro Circuit 304 silencer, and bought a new Acerbis Xseat:
A hard piece to create, building a Carbon airboot (there is a silicon hose between the carburetor and the airboot):
And it fits perfectly:
Starting with the exhaust:
Graphics and finish the bike:
Satisfied
It's a beast to ride, way too fast but very happy with my result. I also posted some of these pictures on Bike Checks, so hopefully I become 'Bike of the Day' once!
Greetings from the Netherlands!
Jos
Last months I've been working on a project for myself, a KX500AF conversion with a '91 engine and a '09 KXF250 chassis. My project is finished now, and I like to share my work with you.
Starting with the 1991 engine:
The 2009 KXF250 rolling chassis:
I want to make the clutch cover divisible, so I cut the carter in pieces:
Developing an answer with SolidWorks to this problem:
Developing a new chain protector:
Developing a new Y part (red parts into existing frame):
Starting cut the frame down:
Making myself some new pieces with a waterjet cutter:
Making the clutch cover:
Making the chain protector:
Insert the Ypart:
Building a new brake pedal:
Making a adaptor for holding the head of the cilinder:
Cut new radiators completely down, and built some new one (I used two new right KXF250 radiators because of the available space):
Bought new pegs, and new Factory wheels:
Making the subframe fit a new Pro Circuit 304 silencer, and bought a new Acerbis Xseat:
A hard piece to create, building a Carbon airboot (there is a silicon hose between the carburetor and the airboot):
And it fits perfectly:
Starting with the exhaust:
Graphics and finish the bike:
Satisfied
It's a beast to ride, way too fast but very happy with my result. I also posted some of these pictures on Bike Checks, so hopefully I become 'Bike of the Day' once! Greetings from the Netherlands!
Jos
Holy shit. Fuckin nice work. Very cool! The pipe, airbox, Y-piece and the assumed trench it leaves. Wow!
The only thing that's irking me is the front fender, but I can't tell if it's because I'm used to seeing the latest gen bikes that have the downwards slanted fenders or if it's mounted funny?
The Shop
But that pipe tho.
It's giving me wood. Serious wood.
Because of the size of the engine, my handmade radiators moved a little bit up to the front, to create a minimun space between the cylinder head and the radiators. So the front fender hits the plastic, black radiator protectors. So it was necessary to put a shim behind two front fender bolts to create a minimum of space. It's not the best looking way, but you are the first guy who reckonized this! No one else has told me the fender looks a little bit different than it should be. But maybe I will find another, better solution for it. Cause its not perfect! And I like it perfect! Maybe I can create an awesome looking carbon front fender, or use a 2014 model fender.
Nice to hear you guys like my work. Its costs me a lot of blood, sweat and tears (and hours and money!) to get it in this beautiful condition. I am a perfectionist.
Another question...how does your bike become 'Bike of the day'? I would like to see my work on the front page of Vitalmx.com!!!
You've got one sweet ride that you should really be proud of.
dogger
I did everything myself, except the exhaust. It's a Fedor Copal pipe. Google his name for more pictures of more great work from this guy!
heres a link to an on-going honda af build you will like.it's another dutch guy building the bike too!
http://www.thumpertalk.com/topic/1088615-cr500af-build/
Very nice work man, well done again!
Just sort that fender!
Pit Row
Honestly, I'm a Honda guy too, I've had a Honda CR500 for 5 years, and I liked that bike very much. Always had in mind to do a AF conversion. But there are, here in Holland, much more CR500AF conversions done than KX500AF conversions. And I wanted something special to build, and I was curious about the KX500 engine, in comparison with the CR500 engine.
It was hard to find a nice, fresh KX500 engine here in Holland, so I bought mine on Ebay. It comes from California, USA.
I've had many reactions on my selfmade divisible clutch case cover. There are a few guys who want me to make the same covers for them.
I wanted to make my cover divisible cause it is a easier way to reach the clutch when necessary. Besides, I had to make it this way. when you want to remove the original clutch cover case off the engine, the case would hook on the aluminum frame on the left side. You can't take it off without removing the complete engine! Not very practical, so I made the case divisible! I also made the case lockable from oil with milling an O-ring into the case. Works perfectly!
I would'nt be surprised if you got a few request's to build some carbon part's aswell as the quality looks superb also.i have a carbon fuel tank for my yz 2-smoke and would love to have a carbon subframe/air box like those that twin air used to make a while back.
You definitely made it your own.
NICE work!!
Beyond sweet - very well done, sir.
Much better now
Post a reply to: KX500AF 2009 Conversion