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Author Topic: The Haas KX500 build. Dyno Doug Haas  (Read 3883 times)

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Offline sandblaster

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The Haas KX500 build. Dyno Doug Haas
« on: March 09, 2022, 06:33:19 AM »
Dyno Doug Hass former Kawasaki Factor Engineer and I have been working on a lot of projects...
Doug has provided me with a lot of technical information for various builds including my land speed attempt.
As you follow this thread you will understand why I named this one "The Haas"

If you have followed any of my builds you will know that I generally try to do something a little different or better than previous builds.
So here is the build plan for this bike.
19-21 KX450 forks, wheels, and brakes. No big deal as I have done that before.
But add to that a 19-21 KX450f rear shock :shock:
Yes... Shocking :o
Some of you may be unaware of this but the reason that you can't use a 450F shock is because there is not enough clearance for the pipe stinger where it passes above the shock reservoir and you would have to flatten it to make it fit.
This build will be a bit of a journey so stay tuned.
If your KX500 does not have these engine guards, it's not a Haas build..


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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #1 on: March 09, 2022, 11:10:45 AM »
There are a few things that have to be done to make a 450F shock fit your KX500 frame..
Here is a pic of the shock after I cut the reservoir off...

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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #2 on: March 10, 2022, 05:21:42 AM »
I removed the stock KX500 peg mounts and had my good buddy Vince Brewer weld on some YZ250 2020 ish foot peg mounts to fit my Titanium Paragon pegs...


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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #3 on: March 11, 2022, 05:31:46 AM »
After that was done I sent the shock, frame, JT Engine Works Gusset kit, and Dyno Doug Haas Engine guards to none other than Dyno Doug Has for more fabrication and weld.


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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #4 on: March 14, 2022, 01:33:22 PM »
And how about a custom made Dyno Doug skid plate..


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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #5 on: March 16, 2022, 04:56:44 AM »
I took the 2019-21 KX450F shock and Cerakoted it in Copper...
I went ahead and did the Unitrak linkage as well...


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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #6 on: March 18, 2022, 04:24:07 AM »
 had Doug weld on this rear brake master cylinder relocation tab for using a 19-21 KX450F master cylinder.


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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #7 on: April 01, 2022, 05:41:07 AM »
What is this?
A custom Dyno Doug skid plate.
It's a one off.
Nothing else will fit this set up..





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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #8 on: June 19, 2022, 04:02:51 PM »
Before I sent this frame off to Doug, I mocked everything up to be sure I would have the proper clearances.
So far, so good 8-)

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #9 on: June 20, 2022, 04:37:12 PM »
I bought these engine mounts and the rear muffler bracket from Jonathon Bell in the UK..

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #10 on: June 21, 2022, 10:22:43 AM »
Doug Haas installed my JT Engine Works Gusset kit..
He even drilled the drainage holes...  :mrgreen:



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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #11 on: June 22, 2022, 04:03:16 AM »
The day I received the frame it went straight to the Powder Coater for some Prismatic Powders Kiwi Green.
While I was waiting for it to get done I ordered up some of Jonathon Bells engine brackets for a little extra bling.
No, I will not be using these bolts for the project :lol:






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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #12 on: July 02, 2022, 03:54:32 AM »
After Powdercoating I always run a tap down all the threaded holes...
Yes... My powder coater plugs the holes off but there is always some residual junk in the threads and I like to torque my bolts down and not have to worry about false readings.

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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #13 on: July 15, 2022, 04:44:46 AM »
After modification The 2019-22 master cylinder fits perfect... And add a little Hammerhead products for some extra bling..
I also like the fact that the KX450F rear brake lever is a little longer than the KX500 rear brake lever.
It offers more leverage and looks great!
Also, the Hammerhead clevis and spring kit eliminates the spring on the rear brake lever.


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Re: The Haas KX500 build. Dyno Doug Haas
« Reply #14 on: August 02, 2022, 05:47:05 AM »
I've been saving these triple clamps for a special project.
Release the Hounds!

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