KX Riders

Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: nikanor on December 07, 2011, 05:36:41 AM

Title: The first in Greece
Post by: nikanor on December 07, 2011, 05:36:41 AM

As the title says, i believe is the first KX500AF in Greece.

A year ago i decided to have a 500cc and keep it forever, it was easy to choose between the CR and the KX cause someone said "f@@k honda the kawi is a beast" and that was it, i start looking for a K5.
I blame you guys and at the same time i really thank you cause i found the AF conversion amazing.
An alou frame for great handling,better suspensions, brakes etc.
But mostly i thank you all for all that infos i have found on this great forum.
Before i start posting some pics i really want to thank some people who help me alot and without them nothing would have happened.
So, many thanks to Kostas Boutos and Chris Fragos from the Boutos R&D Workshop and Dimitris Keramidas from DKracing.
Please it is NOT an advertising.

I have allready introduse my self.
My name is Nikanor i am from Greece Athens and that is my black beauty.


PS. sorry for my English.

Title: Re: The first in Greece
Post by: nikanor on December 07, 2011, 05:57:01 AM

What you are about to see it is made piece by piece and most of the parts come from the US and UK.
The engine is a K5 2001 and it came with electronis and carb. I took it apart and replaced a few parts and now its like new.
The rest of the bike is a KX450F 2006 that i put it together piece by piece.
God blass e-Bay.
I choose the 450 cause it has more space for the engine.
The bike has cost so far 5000? including shipping cost and custom services.

CHAPTER 1
"What we have here?"
When we first put the engine on the frame we notice that we are not going to have any problem with the sprockets and the chain, but we have some issues with the swingarm.
The swingarm it is not from the same bike (frame) even if it is a 2006 year, so we had to make new spacers from an T8 alou.
For those who use their own bike as a donor will not have any problem.

(http://img546.imageshack.us/img546/4526/img00449201105211845.th.jpg) (http://imageshack.us/photo/my-images/546/img00449201105211845.jpg/)

(http://img20.imageshack.us/img20/977/img00448201105211845.th.jpg) (http://imageshack.us/photo/my-images/20/img00448201105211845.jpg/)

 

Title: Re: The first in Greece
Post by: nikanor on December 07, 2011, 06:46:06 AM

CHAPTER 2 "Air box filter"

I use a kx250 98-02 air boot with an alou spacer that we all know by now

(http://img11.imageshack.us/img11/5195/img00510201106091819.th.jpg) (http://imageshack.us/photo/my-images/11/img00510201106091819.jpg/)

(http://img13.imageshack.us/img13/1092/img00515201106101835.th.jpg) (http://imageshack.us/photo/my-images/13/img00515201106101835.jpg/)

(http://img853.imageshack.us/img853/4941/img00514201106101835.th.jpg) (http://imageshack.us/photo/my-images/853/img00514201106101835.jpg/)

(http://img13.imageshack.us/img13/2325/img00516201106101835.th.jpg) (http://imageshack.us/photo/my-images/13/img00516201106101835.jpg/)

(http://img846.imageshack.us/img846/6236/img00494201106052006.th.jpg) (http://imageshack.us/photo/my-images/846/img00494201106052006.jpg/)

(http://img196.imageshack.us/img196/8489/img00518201106101943.th.jpg) (http://imageshack.us/photo/my-images/196/img00518201106101943.jpg/)

(http://img831.imageshack.us/img831/2366/img00519201106101943.th.jpg) (http://imageshack.us/photo/my-images/831/img00519201106101943.jpg/)

(http://img40.imageshack.us/img40/1774/img00520201106101944.th.jpg) (http://imageshack.us/photo/my-images/40/img00520201106101944.jpg/)

(http://img97.imageshack.us/img97/9758/img00521201106101944.th.jpg) (http://imageshack.us/photo/my-images/97/img00521201106101944.jpg/)

As you can see it works just fine

Title: Re: The first in Greece
Post by: kxpegger on December 07, 2011, 01:27:53 PM

Great post!

My SH had a clearance issue at the right top side of the airbox. One of the bolts they used rubbed a nice little groove on the top rear of the oil/nitrogen reservoir of the rear shock. They used a Honda CR250 airboot though. You may not have this issue using the KX250 airboot. Mine only rubbed at near full compression.

Title: Re: The first in Greece
Post by: nikanor on December 09, 2011, 08:19:57 AM

CHAPTER 3 "Y section"

Jfab's frame rails is a very nice solution but i didnot had the time to wait for the rails to arrive so i continued by removing the y section. After spending an hour to clean it was time to remove the holes.

(http://img23.imageshack.us/img23/2792/img00481201106012038.th.jpg) (http://imageshack.us/photo/my-images/23/img00481201106012038.jpg/)

(http://img4.imageshack.us/img4/9666/img00482201106012113.th.jpg) (http://imageshack.us/photo/my-images/4/img00482201106012113.jpg/)

(http://img542.imageshack.us/img542/1740/img00486201106012232.th.jpg) (http://imageshack.us/photo/my-images/542/img00486201106012232.jpg/)

You already have the engine on the right position so you know where to cut the main tube to make room for the exchaust pipe.
Make sure to cut the frame rails when removing the y section high enough after the angle.

(http://img39.imageshack.us/img39/3991/img00479201106012037.th.jpg) (http://imageshack.us/photo/my-images/39/img00479201106012037.jpg/)

If you decide to go this way i suggest to make this little pieces of alou and insert it to frame rail but dont forget to drill a hole so the hot air during the weld to be able to defused inside the rails and leave from the small hoses that the frame has.

(http://img221.imageshack.us/img221/2808/img00955201110261815wl.th.jpg) (http://imageshack.us/photo/my-images/221/img00955201110261815wl.jpg/)

The thicker point is for two reasons a) you know where to stop when you insert it inside the rail and b) it melts when you weld it.
Find some square alou tube T6 and cut the pieces you need.

(http://img4.imageshack.us/img4/9242/img00958201110261818.th.jpg) (http://imageshack.us/photo/my-images/4/img00958201110261818.jpg/)

(http://img594.imageshack.us/img594/2092/img00956201110261817.th.jpg) (http://imageshack.us/photo/my-images/594/img00956201110261817.jpg/)

Now take it to welder

(http://img684.imageshack.us/img684/3783/img00963201110262239.th.jpg) (http://imageshack.us/photo/my-images/684/img00963201110262239.jpg/)

(http://img18.imageshack.us/img18/9572/img00960201110262238.th.jpg) (http://imageshack.us/photo/my-images/18/img00960201110262238.jpg/)

(http://img847.imageshack.us/img847/3294/img00961201110262239.th.jpg) (http://imageshack.us/photo/my-images/847/img00961201110262239.jpg/)


Ok? You have it back?
Start triming it now for better look.

(http://img20.imageshack.us/img20/2359/img00966201110271128.th.jpg) (http://imageshack.us/photo/my-images/20/img00966201110271128.jpg/)

(http://img196.imageshack.us/img196/8439/img00965201110271128.th.jpg) (http://imageshack.us/photo/my-images/196/img00965201110271128.jpg/)

See you tomorrow

Title: Re: The first in Greece
Post by: azracer19 on December 20, 2011, 09:14:49 AM

thanks for the great idea... did you have the inserts milled? to fit?

Title: Re: The first in Greece
Post by: nikanor on December 27, 2011, 04:25:34 AM

Yes, but not to much, you want them to be a little bit tight.

I am having some issues with the server, it wont let me to upload pictures or i make a mistakes
I get a 404 server not found message, something like that everytime i click post or preview

Title: Re: The first in Greece
Post by: nikanor on January 29, 2012, 12:40:56 AM

Engine mounts

Lower engine mounts

(http://imageshack.us/photo/my-images/828/img01091201111131710.jpg/])

(http://img828.imageshack.us/img828/7146/img01091201111131710.th.jpg)


[img=http://img802.imageshack.us/img802/7377/img01089201111121931.th.jpg]http:// (http://imageshack.us/photo/my-images/802/img01089201111121931.jpg/)(http://)

(http://)[img=http://img10.imageshack.us/img10/3474/img01088201111121931.th.jpg]http:// (http://imageshack.us/photo/my-images/10/img01088201111121931.jpg/)(http://)

(http://)[img=http://img838.imageshack.us/img838/8240/img01087201111121930.th.jpg]http:// (http://imageshack.us/photo/my-images/838/img01087201111121930.jpg/)(http://)

(http://)[img=http://img17.imageshack.us/img17/1438/img01028201111042049.th.jpg]http:// (http://imageshack.us/photo/my-images/17/img01028201111042049.jpg/)(http://)

(http://)[img=http://img221.imageshack.us/img221/9996/img01027201111042049.th.jpg]http:// (http://imageshack.us/photo/my-images/221/img01027201111042049.jpg/)(http://)

Title: Re: The first in Greece
Post by: nikanor on January 29, 2012, 12:43:42 AM

More pictures of the lower engine mounts

(http://)[img=http://img571.imageshack.us/img571/7051/img01025201111042048.th.jpg] (http://imageshack.us/photo/my-images/571/img01025201111042048.jpg/)(http://)

(http://)[img=http://img267.imageshack.us/img267/7207/img01023201111042047.th.jpg] (http://imageshack.us/photo/my-images/267/img01023201111042047.jpg/)(http://)

Title: Re: The first in Greece
Post by: Brute on January 29, 2012, 03:03:45 AM

Fun project. Has to be a bugger getting parts! My Grandfather was Greek. Some of the family have made the trip there to see the area where he lived. Best of luck on the project!

Title: Re: The first in Greece
Post by: nikanor on January 31, 2012, 04:12:14 AM

Thanks you, you are all welcome to visit GR and if you think i can help let me know.

Engine mounts
Head stay

(http://)[img=http://img580.imageshack.us/img580/9493/img00937201110201843.th.jpg] (http://imageshack.us/photo/my-images/580/img00937201110201843.jpg/)(http://)

(http://)[img=http://img838.imageshack.us/img838/7690/img00938201110201844.th.jpg] (http://imageshack.us/photo/my-images/838/img00938201110201844.jpg/)(http://)

(http://)[img=http://img828.imageshack.us/img828/3747/img00954201110242201.th.jpg] (http://imageshack.us/photo/my-images/828/img00954201110242201.jpg/)(http://)

(http://)[img=http://img706.imageshack.us/img706/3779/img00952201110242200.th.jpg] (http://imageshack.us/photo/my-images/706/img00952201110242200.jpg/)(http://)

(http://)[img=http://img845.imageshack.us/img845/5392/img00951201110242200.th.jpg] (http://imageshack.us/photo/my-images/845/img00951201110242200.jpg/)(http://)

(http://)[img=http://img42.imageshack.us/img42/3889/img00939201110201850.th.jpg] (http://imageshack.us/photo/my-images/42/img00939201110201850.jpg/)(http://)

(http://)[img=http://img809.imageshack.us/img809/9321/img01130201111201731.th.jpg] (http://imageshack.us/photo/my-images/809/img01130201111201731.jpg/)(http://)

Title: Re: The first in Greece
Post by: Brute on January 31, 2012, 11:41:50 AM

Nice looking brackets! Were they bent, welded, or machined? Still have parts coming for my mostly stock KX5. Weather cleared up a bit today in Washington State. Made me want to get one of the other bikes out for a ride!

Title: Re: The first in Greece
Post by: nikanor on February 01, 2012, 07:04:40 AM

Radiators

I bought the stock radiators but i used only the right one (clutch side), for the left side i use one from a YZ85 '00-'02.
The left one is to long and you will have issues with the pipe
I also used silicone hoses from samco.
We cut and rotate a few bends as you can see on the pics.

(http://)[img=http://img52.imageshack.us/img52/4378/img00546201106181407.th.jpg] (http://imageshack.us/photo/my-images/52/img00546201106181407.jpg/)(http://)

(http://)[img=http://img267.imageshack.us/img267/5854/img00545201106181406.th.jpg] (http://imageshack.us/photo/my-images/267/img00545201106181406.jpg/)(http://)

Title: Re: The first in Greece
Post by: nikanor on February 02, 2012, 06:21:17 AM

Radiators and silicone hoses

(http://)[img=http://img543.imageshack.us/img543/9687/img01124201111192353.th.jpg] (http://imageshack.us/photo/my-images/543/img01124201111192353.jpg/)(http://)

(http://)[img=http://img585.imageshack.us/img585/9186/img01111201111161935.th.jpg] (http://imageshack.us/photo/my-images/585/img01111201111161935.jpg/)(http://)

(http://)[img=http://img59.imageshack.us/img59/3640/img01110201111161934.th.jpg] (http://imageshack.us/photo/my-images/59/img01110201111161934.jpg/)(http://)

(http://)[img=http://img850.imageshack.us/img850/4832/img01109201111161934.th.jpg] (http://imageshack.us/photo/my-images/850/img01109201111161934.jpg/)(http://)

(http://)[img=http://img833.imageshack.us/img833/6793/img01108201111161934.th.jpg] (http://imageshack.us/photo/my-images/833/img01108201111161934.jpg/)(http://)

Title: Re: The first in Greece
Post by: kxpegger on February 02, 2012, 11:44:17 AM

Looks like you're close to the finish line! We're going to need a ride report soon! 8-)

Title: Re: The first in Greece
Post by: nikanor on February 03, 2012, 04:06:50 AM

The bike is already done, now i have the time to post.
I am trying to do a "how to" post.
As for the ride report! What can i say i look like jocker with that big smile and my hands are a little bit longer

Title: Re: The first in Greece
Post by: nikanor on July 18, 2012, 08:15:34 AM

Final pics

(http://[URL=http://imageshack.us/photo/my-images/600/bbo5159.jpg/][IMG]http://img600.imageshack.us/img600/9913/bbo5159.th.jpg)[/URL]
[/img]

(http://[URL=http://imageshack.us/photo/my-images/196/bbo5144.jpg/][IMG]http://img196.imageshack.us/img196/204/bbo5144.th.jpg)[/URL]
[/img]

Title: Re: The first in Greece
Post by: nikanor on July 18, 2012, 08:16:54 AM

(http://)(http://img196.imageshack.us/img196/204/bbo5144.th.jpg) (http://imageshack.us/photo/my-images/196/bbo5144.jpg/)(http://)

(http://)(http://img600.imageshack.us/img600/9913/bbo5159.th.jpg) (http://imageshack.us/photo/my-images/600/bbo5159.jpg/)(http://)

Title: Re: The first in Greece
Post by: nikanor on July 18, 2012, 08:35:28 AM

The hardest part of the project was the exchaust pipe

I used a procircuit chamber, works type that really needs maintenance every day from a CR500 and a 304 silencer

We totally cut the pipe in every weld point and with some duct tape we secure it and marked it

We come up with the idea of making that part of steel to connect the inlet.

(http://)(http://img189.imageshack.us/img189/7807/img01218201111291131.th.jpg) (http://imageshack.us/photo/my-images/189/img01218201111291131.jpg/)(http://)

Title: Re: The first in Greece
Post by: nikanor on July 18, 2012, 08:39:01 AM

Some final pics

I hope you like the result

(http://)(http://img444.imageshack.us/img444/1737/bbo5362.th.jpg) (http://imageshack.us/photo/my-images/444/bbo5362.jpg/)(http://)

(http://)(http://img716.imageshack.us/img716/6182/bbo5319.th.jpg) (http://imageshack.us/photo/my-images/716/bbo5319.jpg/)(http://)

(http://)(http://img26.imageshack.us/img26/879/bbo5267.th.jpg) (http://imageshack.us/photo/my-images/26/bbo5267.jpg/)(http://)

(http://)(http://img840.imageshack.us/img840/8245/bbo5167.th.jpg) (http://imageshack.us/photo/my-images/840/bbo5167.jpg/)(http://)

(http://)(http://img819.imageshack.us/img819/9117/bbo5154.th.jpg) (http://imageshack.us/photo/my-images/819/bbo5154.jpg/)(http://)

(http://)(http://img10.imageshack.us/img10/8544/bbo5145.th.jpg) (http://imageshack.us/photo/my-images/10/bbo5145.jpg/)(http://)

Thank you all for the infos

Title: Re: The first in Greece
Post by: Brute on July 18, 2012, 11:35:14 AM

Very nice!

Title: Re: The first in Greece
Post by: nikanor on September 07, 2012, 01:23:12 AM

What year you think is this frame? You think its good idea to put a K5 on this?

(http://)(http://img820.imageshack.us/img820/7475/img00287201208311349.th.jpg) (http://imageshack.us/photo/my-images/820/img00287201208311349.jpg/)(http://)

Title: Re: The first in Greece
Post by: nikanor on April 08, 2013, 03:08:15 AM

I am thinking of selling my AF conversion, anyone intresting?

Thanks

Title: Re: The first in Greece
Post by: nikanor on April 08, 2013, 04:43:40 AM

some pictures

(http://)[img=http://imageshack.us/scaled/thumb/854/img00548201212021020.jpg] (http://imageshack.us/photo/my-images/854/img00548201212021020.jpg/)(http://)

(http://)[img=http://imageshack.us/scaled/thumb/845/img00546201212021019.jpg] (http://imageshack.us/photo/my-images/845/img00546201212021019.jpg/)(http://)

Title: Re: The first in Greece
Post by: sandblaster on April 08, 2013, 05:50:34 AM

(http://imageshack.us/a/img854/9068/img00548201212021020.jpg)

The other pic was too small  :-(

Title: Re: The first in Greece
Post by: Motorrad on April 08, 2013, 06:06:58 AM

Quote from: sandblaster on April 08, 2013, 05:50:34 AM

(http://imageshack.us/a/img854/9068/img00548201212021020.jpg)

The other pic was too small  :-(

very interesting clutch cover... wouldnt you say blaster

Title: Re: The first in Greece
Post by: sandblaster on April 08, 2013, 07:27:29 AM

You know it  :-D

Title: Re: The first in Greece
Post by: nikanor on April 09, 2013, 07:43:50 AM

The price will be at 5000$ but you can make an offer.


(http://)[img=http://imageshack.us/scaled/thumb/43/img00546201212021019.jpg][/url(http://)]

I hate to say that but the bike must go so i am thinking also of start parting this out
 (http://imageshack.us/photo/my-images/43/img00546201212021019.jpg/)

Title: Re: The first in Greece
Post by: nikanor on April 10, 2013, 05:14:09 AM

(http://)[img=http://imageshack.us/scaled/thumb/829/img00548201212021020.jpg] (http://imageshack.us/photo/my-images/829/img00548201212021020.jpg/)(http://)

(http://)[img=http://imageshack.us/scaled/thumb/10/bbo5145.jpg] (http://imageshack.us/photo/my-images/10/bbo5145.jpg/)(http://)

Title: Re: The first in Greece
Post by: nikanor on May 07, 2013, 03:27:12 AM

Anyone intresting to exchange parts?

Iam looking to convert my KX500AF to a KX450F
Engine with full electronics and carb,frame,subframe,radiators with hoses,air-box filter,exchaust silenser & chamber,clutch & throttle cable.

2010 or newest

nikanor44@hotmail.com for infos

Thanks