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Author Topic: KX500 going into a CRF250X  (Read 18214 times)

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Offline gortex

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KX500 going into a CRF250X
« on: October 31, 2009, 01:13:03 PM »
Here some pics of my 3 week old KX500AF
Got a decompression valve in the head which is opened with a hot start lever
Just got the KLX 400 rekluse start clutch in her a week ago thanks doordie for all your info on this.
Got the DEP Silencer on and waiting on the DEP CR500 pipe to come into the country (i'm from New Zealand)
The CR500 pipe on there at the moment has got so any holes in it that one time i start the bike with a silencer plug still in it!!!
Using the old plastics for now but will be a black monster energy bike soon.
I will like to thank everyone that has posted on here, you have being a great help.
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Offline ID KX500

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Re: KX500 going into a CRF250X
« Reply #1 on: October 31, 2009, 02:58:24 PM »
Sweeeet
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Offline KXcam22

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Re: KX500 going into a CRF250X
« Reply #2 on: November 01, 2009, 03:10:08 AM »
The motor fits very nicely in there. Can you describe the work it took to get it in there.  It will be helpull for others trying to build one. I can't wait to see the finished product.  Thanks. Cam.
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Offline Danger4u2

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Re: KX500 going into a CRF250X
« Reply #3 on: November 01, 2009, 03:27:36 AM »
Your project is coming along nicely.  If you would please,  give us a close up picture of the release so we can see how it sticks out by the pipe.
Do you think it is susceptible to damage in the event of a right side "get off" ?
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Offline KXcam22

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Re: KX500 going into a CRF250X
« Reply #4 on: November 01, 2009, 06:00:31 AM »
Are those Motoz tires on that thing?  How do you like them. Cam.
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Offline gortex

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Re: KX500 going into a CRF250X
« Reply #5 on: November 03, 2009, 06:33:17 AM »
Ok I'm using Shinko Holeshot MS 540 tires front and rear, they are awesome in the wet and mud will be going to their harder tire for the summer here in the next month or so.
I attached some more photos of the compression valve, and no the valve looks to be well protected with the the rads and pipe.

The crf250 gen4 frame is vary close to the kx250f 09 frame, had to drill the swingarm hole to 17mm and shave a 1mm from the motor to fit into the gap.
Also shorten the stock spacers, this makes the motor a nice tight fit and lines up the chain straight off.
All new engine cradle was made out of solid alloy and using the stock Y section which was moved up just below the rad mounts.
The top crf engine mount fits straight to the kx500 even using the stock brackets!
Getting a custom graphics kit made up for it and just got my hands on a set of RG3 20mm triple clamps.
Thinking about getting the frame anodised or powercoated black at the moment to go with the black plastics etc, any ideas will be great.
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Offline gortex

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Re: KX500 going into a CRF250X
« Reply #6 on: November 03, 2009, 03:35:37 PM »
Hope these pics help with any questions
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Offline dubious01

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Re: KX500 going into a CRF250X
« Reply #7 on: November 03, 2009, 05:24:43 PM »
Thats awesome, I found a local 05 CRF450 with blown motor, and a 06 RMZ450 with blown engine.
Once i have a look at the condition of these bikes I am going to decide which one.
The 05 CRF 450 had rave reviews , and the suzuki's have always railed and cut inside corners like a cat on a rug.
I don't think I can go wrong with either one especially for the price I get a modern chasis for! ~$1500! haha!

Then all I will need is a suspension revalve, a few fresh plastics and Stewarts motor!

woot woot!

Looks like the rear brake pedal is interfereing allot. Is it due to the clutch cover you have, or will stock be in bad shape there too?
« Last Edit: November 03, 2009, 05:32:10 PM by dubious01 »
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Offline gortex

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Re: KX500 going into a CRF250X
« Reply #8 on: November 03, 2009, 07:30:55 PM »
One my mates got a yz490 in a 05 RMZ450, just like the crf450 and rmz450 i choose this bike as it was the gen4 honda frame with blown motor for $1200 nzd these sell for around $12,000 new here.
As for the foot brake, it's coming off as i'll be using the rekluse left hand rear brake kit to go with the rekluse clutch now that i don't use the clutch lever any more.
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Offline dubious01

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Re: KX500 going into a CRF250X
« Reply #9 on: November 04, 2009, 12:09:33 PM »
Cool, and congrats!
will rear brake pedal clearance be an issue with my stock kx500 clutch cover? :?

I was thinking it will be an awesome sleeper ,  8-)especially in the RM chasis, as nobody would ever suspect a 500 in a Suzuki LMAO, especialy if I remove the kips and kawasaki logo's, they will know something is up when they end up eating major roost though.... bahahaaaa :evil:
« Last Edit: November 04, 2009, 12:12:35 PM by dubious01 »
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Offline gortex

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Re: KX500 going into a CRF250X
« Reply #10 on: November 04, 2009, 03:59:56 PM »
No, you will have heaps of room, my clutch cover is a total of 15mm out from the stock one.  I spaced it 10mm for the rekluse and the cover itself is 5mm thick.
Like your idea, i have people still think it's a four stroke because of the big muffer, then they think it's a cr250.....but once it's running they drop those idea's and think it's a cr500af.  It's only when they see the Kawasaki on the side cover that they click lol.
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Offline dubious01

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Re: KX500 going into a CRF250X
« Reply #11 on: November 05, 2009, 04:47:21 AM »
Cool,
Thanks for the info , much appreciated!
so what intake boot have you got on the airbox?

I had a black CR500af that I built, black looks great when new, but gets beat looking real quick if you ride in brush, or fall down alot ! LOL
Its all a matter of choice I think.

Any bike as sinsiter as a Kx500 should be mean green, or sinister black IMO, but I like the sleeper stock new 250 2 stroke idea too....LOL

If you replace the ignition cover with a boyesen, the kawi emblem will be gone, just the kips one I will grind off, then sand blast the jug to make it blend in like it was never there...ahahahaaaa  :evil:

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Offline gortex

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Re: KX500 going into a CRF250X
« Reply #12 on: November 09, 2009, 06:46:27 AM »
Using the stock Kx500 airboot with a alloy plate used to bolt it to a new crf250r airbox
Will be getting a boyesen ignition cover in the near future.
This week being getting the tank modded to make more clearance for the spark plug., so the tank can sit right.\
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Offline dubious01

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Re: KX500 going into a CRF250X
« Reply #13 on: November 10, 2009, 03:00:25 PM »
Cool,
Thanks bro!  :mrgreen: 8-)
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Offline gortex

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Re: KX500 going into a CRF250X
« Reply #14 on: January 04, 2010, 06:42:47 PM »
Updated pics she's getting closer too being finished every month all goes on the $$$
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