completed KX500AF build in germany

[uncle-k]

hello from germany,
its my first post here, and i like to show my finished conversion.

i used a 2009 KX250f Frame








some facts:
i used the original Y-piece and frame rails from a GSXR1100, they measure 30x30mm and slip over the cut original 25x25 mm rails.
the welding was done by an expert who has done a lot aluminium frame work. the frame was heat treatened.
the pipe is a special pro circuit pipe for the original kx500 to accept an oversive tank from ims or zip-ty, i think.

i only had to change the last part of the pipe to match a unchanged cr500 silencer.
i used right hand kx250f radiators `08 on both sides.
the headstay was fitted to the original mounts on both sides using quite strong material.
the original airbox boot was cut 1inch from the airbox and a `02 Cr250 boot slipped over it. i used a lot special black glue to fix it.
the engine has a stroked crank from a sidecar, 90mm stroke. the v.h.s. ported cylinder has std bore 86mm = 523cc
boyesen rad valve and reed spacer.

suspension is an older showa b-kit fork and a s?lva shock

i am happy answering any questions..

greets !

[andydunne]

That is very nice, fairplay
Where are you from in Germany?, im Irish btw. I was working in East Germany about a month ago, very different to Ireland

[jBernard]

nice find on the gsxr Y. how'd you discover that it fits?
welds look factory, nicely done there as well.

on the right side of the Y it looks like the pipe is pretty close. does the pipe clear or did you cut a relief? i see a weld seam but it may just be for the downtube joint.

[kxpegger]

Nice work! Now hammer it!

[dave916]

NICE
 any issues  with the stroked motor

[SS109]

...
i used the original Y-piece and frame rails from a GSXR1100, they measure 30x30mm and slip over the cut original 25x25 mm rails.

 I would love to hear more about this. So, you are saying that you used the Y section and frame rails from a GSXR, right? What year of GSXR1100 did you pull this from? Got any close up or build pics pics of how it slipped in place?

BTW, it looks sweet!

[uncle-k]

thanks for the positive feedback!

@andydunne
i m from the home of VW: wolfsburg west germany. and even that is different to east germany.

@jBernard
i had a `94 gsxr1100w frame from a streetbike motor conversion. it was just an idea and good luck.
the welds really look factory, the man who done it does nothing but welding aluminium.
the pipe is very close because of the thicker rails but they clear a few mm. the pipe was also a great find and good luck. from damagedgoodsglobal usa btw

@dave916
not yet. but had to adjust the compression ratio carefully. after leaning the jetting my brother said. "its the first engine he rode with too strong bottom end"...

@SS109
i used the original KX250f Y-section and frame rails from a GSXR1100w `94
the rails are long enough on both sides, so you can cut just the part you need from the gsxr frame.
they are 25x25mm on the inside, perfect.
you can also use the original threads on the inside for the front motor mount. i build 2 adapter plates from strong material. i ll post pictures from that.
unfortunately, there are no pics from the buid, i didnt thought i would post it someday...

[SS109]

@SS109
i used the original KX250f Y-section and frame rails from a GSXR1100w `94
the rails are long enough on both sides, so you can cut just the part you need from the gsxr frame.
they are 25x25mm on the inside, perfect.
you can also use the original threads on the inside for the front motor mount. i build 2 adapter plates from strong material. i ll post pictures from that.
unfortunately, there are no pics from the buid, i didnt thought i would post it someday...

Thank you. I would love to see those adapters when you get the chance!

[Dutch-K5 Fan]

Hi Uncle-k, great bike.

Do you ride at Wolfsburg-Velstove? And do know if there are any tracks north of the Nedersaksen, near Amt Neuhaus

I'm from Holland just under Amsterdam.
A customer from works has his farm at kaar?en Amt Neuhaus. Would like to ride once in that area.

Dutchie

[andydunne]

thanks for the positive feedback!

@andydunne
i m from the home of VW: wolfsburg west germany. and even that is different to east germany.

I was working in a town called Munchenburg, about 1hour east of Berlin, pretty close to Poland. Not a nice place really, especially at 30deg C on a huge pig farm and biogas plant

[uncle-k]

@Dutch-K5 Fan

velstove was closed 2 years ago    in the 90s it was a 500cc championship track, i remember gert jan van doorn doing the biggest jumps on his cr500

there are 4 tracks near kaar?en:

klein krams (30km) www.mc-klein-krams.de
vellahn (30km) www.mc-vellahn.de
kuhstorf (40km) www.kuhstorf.kcmtv.de
schwartow (40km)

cheers,
alex

[Caddy 16v]

Sehr sch?ne KX500AF! Gut mal einen Landsmann hier zu treffen, obwohl ich nach Kanada ausgewandert bin.

Gruss in die Heimat, Bj?rn

[Dutch-K5 Fan]

Thanks Alex.
Next week I have to work in Kaar?en with my boss.
Maybe we take a look at some tracks.

That Su#$& that velstove is closed. Amsterdam closed a few years ago, still mis it to have a track nearby.

Gert Jan van Doorn still go's very fast, he worked for a GP team 15km from my house. That was with Marc de Reuver and Kevin Strijbos at Beursfoon.  When the go practice, gert was faster then "his" two rides.
That for a man who rode his first gp befor those two were born

Dutchie

[uncle-k]

i have to fix my clutch at the moment.
that means i had to take the engine out of the frame because the clutch cover cannot be pulled with installed motor   
here the requested pictures:


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