KX500AF Build - Finished!

colson973
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colson973
Edited Date/Time 2/12/2014 7:11pm
Hey Guys

My name is Clay and I own a company called PDR Performance up in MN. I am currently working on a fun bike build project for a guy that I thought everyone would like to check out. I will post pictures and updates regularly as the project progresses. Here is a list of things being done to the bike.

Chassis:
Complete tear down and clean
Remove engine mounts no longer needed
All new bearings
Design a better fitting are box
All new plastic and graphics
Wheel kit, green hubs and black rims
Fully rebuild front and rear brakes
dress up goodies!

Motor:
BIG BORE 540cc kit.
Porting
Rebuild crank and lower end
Cases replaced due to original ones being damaged
Boyesen rad valve
cleaning and dress up
Dyno tuning in the end to see what it puts out!

Here are the starter pictures. Not too many yet but I will start taking more now that the thread is started.












Frame is all cleaned up besides some detail work
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JM485
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JM485 10/24/2013 10:06pm
10/24/2013 10:06pm
Holy crap, a 540! 500cc of raw 2-stroke wasn't enough for you!Cool Looking really good so far, looking forward to seeing some more progress.
colson973
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colson973 10/28/2013 11:33am
10/28/2013 11:33am
Here is some more progress I have made in the last week. All new bearings are in the linkage and swingarm, fook pegs where blasted and re powder coated, and some misc parts are going on. Still waiting on a lot of parts. Will have another up date next week! Thanks for looking!

Linkage Cleaned

All new bearings are in and bolts and cleaned





Got a couple nasty marks on the swing arm but after a little more cleaning and graphics you wont even know they were there.
Foghorn
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Foghorn 10/29/2013 6:37am
10/29/2013 6:37am
Looking good. Some of those OEM welds are a little lumpy.

The Shop

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colson973
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colson973 10/29/2013 8:28am
10/29/2013 8:28am
Not all welds are OEM. This frame was coverted when the customer bought the bike to fit the 500 motor. The original bike was a 2006 KX450F. The welding was not done by me.
Foghorn
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Foghorn 10/29/2013 9:36am
10/29/2013 9:36am
I hear you. The Y welds actually look better, at least in the pics, from some of the welds on the swing-arm and cross-member where the sub-frame bolts up. Still acceptable though, just not a perfect stack of dimes. Nice project.
fouledplugs
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fouledplugs 10/29/2013 1:53pm
10/29/2013 1:53pm
What proccess and products were used to clean the frame? Looks on par if not better than showroom day 1!!

Im planning on cleaning up a frame summer 14 and I was curious of the process.


Awesome progress!
colson973
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colson973 10/29/2013 6:35pm
10/29/2013 6:35pm
Lots of elbow grease!!! First you need to clean the frame very well to remove all the oils, heavy dirt, and grease. Then I like to use Mag etching cleaning along with a fine scotch brite pad. This will cut through all the stains and remaining dirt. Rinse the frame and then repeat the etching 1 more time. Then the final step I do after the frame is totally dry is to hand detail all the welds and tight areas with a dremel and hit the big areas with a scotch brite pad to get all the lines going the same way. From here you can start polishing but I prefer the brushed look!
colson973
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colson973 10/31/2013 7:51am
10/31/2013 7:51am
Finally got some parts coming in and the ebay engine cases (old ones where totally trashed)

Box of parts, plastic, brakes, more bearings, new step seat, other billet goodies

Boyesen Rad valve and ignition cover

Gotta have a little Carbon Fiber!

Sneak peak of what the motor finish will look like once done!
TeamGreen
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TeamGreen 10/31/2013 3:54pm
10/31/2013 3:54pm
After having too many KX500s to count, I can honestly say that there's NO NEED for the 540 kit. A well BALANCED and carefully assembled 500 is about as good as it get's. Balancing the crank pays HUGE dividends. Building your trans like you would any really good gear-box is a big plus, too. The 500 motor balances out pretty nicely...VERY noticable impovemnt in the harmonics and vibration.

I've got a Team Green built "Desert" 500 at the shop and it runs Soooooo smooth that I'd swaer it's an old "SR" MX Nationals Motor.

Is that an '06 450 frame?
colson973
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colson973 11/1/2013 5:47am
11/1/2013 5:47am
Yes 2006 frame and chassis. The descision to do a 540 kit was based more on the fact that the cylinder was shot any ways and needed to be replated or sleeved. The cost for the 540 kit was basically the same and the customer I'm building this for is just looking for a really fun and off the wall bike and the 540 kit is something you dont see too often (for obvious reasons!). So we thought it would be something fun to try and show off. We are looking into crank balancing.
colson973
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colson973 11/6/2013 5:59am
11/6/2013 5:59am
Busy weekend and a business trip on Monday and Tuesday put me behind a little on the bike but I did make a little progress. Got the old cases and intake mounted up to start re-designing the airbox. Last guy who made it didnt do the best job and the air filter cage pulled out of the box. So I'm going to build it right! I will be installing a loud mouth intake and making all aluminum adaptor plates so everything is bolted together like it should be. Here are a couple pics of what Im starting with.



The alignment when its finished will be better than the below picture. The boot can easily be pushed over more that half the gap with no issues.

JBernard_401
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JBernard_401 11/6/2013 11:18pm
11/6/2013 11:18pm
that first pic looks familiar. was this bike for sale on forums a couple months ago?

You should post up on KXriders.com. we have a subforum with AF builds. those guys know their stuff about the KX5 over there!

this is a pretty good looking build. will be welcomed!
colson973
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colson973 11/15/2013 8:23am
11/15/2013 8:23am
Well Im back with more parts in stock and a little more progress. Front end is coming together. Rear brakes are rebuilt, Engine cases are being modified to fit, and the loud mouth intake came in. Still some work to do on the intake but its getting much closer and should be much better than the previous one.









RMRider1
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RMRider1 11/15/2013 7:00pm
11/15/2013 7:00pm
Nasty build, nasty bike of sho!
colson973
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colson973 12/9/2013 8:22am
12/9/2013 8:22am
Finally found some time to get the lower end of the motor together and move ahead on this. Pushing to finish this in December so stay tuned for more pics.







Pit Row

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colson973
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colson973 12/31/2013 6:03am
12/31/2013 6:03am
Finally got more motor stuff in and got this thing looking like a bike. Next step is finishing the air box and then juts putting her back together. Here are the photos of what ive been up to.

Little polishing on the head

Piston got moly coatings on the sides and a ceramic coating on top

Cylinder Cleaned up

Black side case turned out nice!








Travis_Hudson
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Travis_Hudson 12/31/2013 11:04am
12/31/2013 11:04am
That thing is bad ass! i can't wait to see it all back together!
fosheezie
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fosheezie 12/31/2013 7:51pm
12/31/2013 7:51pm
that thing is gonna be a beast! nice work man, that motor is spotless
colson973
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colson973 1/13/2014 10:47am
1/13/2014 10:47am
Finally got the last hard piece of this puzzle finished. The air box. Last guy that built this just had 1 adaptor plate and used big washers and a tube of appoxy to seal it up. It ended up pulling apart and thats what blew the motor. So I think this will be much stronger and better sealing. Plus it looks awesome!













colson973
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colson973 1/31/2014 6:32am
1/31/2014 6:32am
Well here is the bike basically finished. This is the first mock up. Its torn back down now for some mods to the pipe and silencer mounts (the last guy just desided not to run any!) and blue radiator hoses.



souster4
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souster4 1/31/2014 10:09am
1/31/2014 10:09am
Looks great. What process was used to clean up the linkages, and the rear brake unit? And the engine?
Joko
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Joko 1/31/2014 3:16pm
1/31/2014 3:16pm
What company did your 540 kit? Who balanced your crank? What carb are you gonna use? Flywheel weight? I just picked up a 540 cylinder ported by RPS in So Cal, so I need to do the crank, carb and flywheel wt. Thinking of using a lectron carb, and modifying the pipe to match the 540cc's..,,
colson973
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colson973 2/12/2014 5:50am
2/12/2014 5:50am
Here are some of the last pictures. Got the pipe finished and got this monster running! Sounds awesome with a little bit shorter silencer. Please pray my customer doesn't kill himself on the first ride! =]]

Custom Blue Hose Kit


Dents removed and the pipe was re-finished and then colored for a factoy look without the work of a natural pipe =]


2nd view


Silencer shortened 3 inches and fitted to work with the OEM bracket. Looks factory and saved the work of making a mount


Finished Product!

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