k5 klx 450r conversion

[Twosmokerfan]

Well everyone,

The end is in sight and the master of aluminium fabrication worked his magic on the weekend.  I have since dressed all the welds and you can't even tell there are inserts.

The master at work prepping the welds.


Welds complete (Right hand side)


Front


Welds cleaned up



Mounting of the MZB ignition on the LHS of the rear engine bracket


Engine installed and bolted up tight


Final exhaust clearance


I only finished this today, and everything else is going on the bike tomorrow. Hope to kick it over inthe next few days.

TSF

[kwakman]

looks great.are those kx5 rads or 450 ones?

[Twosmokerfan]

Thanks mate,

I bought a set of klx450 radiators off ebay and they are the 40mm deep ones.  I did this so I can still use KLX radiator braces as I race and ride in the bush, so am keen to use protection  .

The standard radiators fit perfectly with the exception of the LHS lower water outlet.  I could have run the hose under the pipe, but decided to spin it upwards and over the cylinder head to meet up with the outlet from the other radiator.  I kept the water flow almost identical to the KLX set up, and even used the 'Y' piece to supply the suction side of the water pump.

TSF

[kxpegger]

Looking forward to the ride report! Excellent work!

[500donk]

Congrats on the build twosmoker!

Thats going to be a real head turner in the bush up there mate. Glad it all came together. That things the king of Enduro's.

[Twosmokerfan]

Thanks Mate.  I sure it will turn heads at the trail rides and enduros I go to. I thought you were going over to the Carribbian (spelling?).  You back up north or in Sydney?

Now all I have to do is get the decomp valve and the electric start sorted (letting the wife calm down first) then I am all set.  That is the next project on the KLX, and just think the Battery and charging system is all there ready to go.

Riding it at the Gympie Trail ride this weekend and fine tuning it.

[500donk]

Yeah Kim in the Caribbean. Had a ride of the af before christmas in Sydney though. It got the blood pumping after not riding for 6 months before.
Electric start on a 500, what a luxury! Is there anyway that she can be rego'd up there? Enjoy the riding anyway mate.

[Twosmokerfan]

Well Ladies and Gents.  Final Pics are here.  Rode it at Killarney Border Ranges Trail Ride on the weekend, and all I can say is OMFG.

This thing is a monster. I had a mate on a late model WR450, 3rd gear roll on, and he had no chance.  It is the torque monster.  The ride was very wet in places and the 4T lovers were boiling bikes, and stuck on hills, but the KLX500 just chugged up hills.  I chose 14-50 gearing (mainly because the KX had a 14t, and the KLX had a 50t on the rear), and that was perfect, if not a tad high for the single track.

I have modified a wiring diagram to help those that want to do the same with a KLX.  The weight difference is very noticable and the KLX is more manageable (in a weight sense) that the 4T.  One thing though, ye must respect the right hand, as it gets up and really moves without revs.

I would recommend doing the conversion if you can get your hands on a KLX.  On thing though, it absolutely sucked the juice.  I was flat our getting 40km out of 7litres.  I might need to check the carby, as it wasn't oiling up the plug, but it was definately getting too much fuel.

Here are two pics of the finished product.  






One question I do have is, Has anyone used a 38mm air striker carb?  If so, what difference does it make?

Thanks for all the help.  I will put togeter a build guide when I finish some assignments first.

TSF

[royceymon@hotmail.co.uk]

awesome ...cant say much more.

[Kiwi500]

TSF, That is awsome, good to see the beast finished.
As usual, Bike parked up since Jan, too busy to ride...bla bla bla.....

Will need to get onto this conversion this winter, just need the $$$$$ KXF's are just about being given away over here now !!

Cheers
Grant

[sandblaster]

Very nice job!
My K5's all suck a lot of juice.
I think your mileage is about par.

[andydunne]

Awesome build!
These af builds are a real work of art!