'09 500AF build

[jBernard]

finally got engine mounts and headstay in and got her welded up. big step finished yesterday so i'm super pumped up.
now engine comes out and on to some cosmetic pieces and non-chassis stuff.

i made some beefy engine mounts, each mount is custom height and width for that space. used a nice fat chamfer for the standoff for weight distribution. theres about .200 of thickness touching the frame rails so they are super sturdy. only had to trim one width about .025 to get it to fit in too, so they are nice and tight.

on the headstay i went with a side plate design, i'll grab some pics of it welded in better, but thinking of using some thick .250 7000 series aluminum laser cut out for each side, hopefully its sturdy enough.

[Brute]

Very nice! Pretty welds too!

[sandblaster]

Very nice, very clean, great job!
Thanks for posting those pics.

[kxpegger]

Looking Good!

[cmotodad]

Are the rails made from solid stock or tube? Looks awesome

[jBernard]

thanks guys!

tubing is 1" square, .125" wall, 6063 T52

[jBernard]

pic of headstay in place. a triangular headstay mount would have been more rigid, but wanted to have enough clearance to get engine out.



engine mostly apart. have some tricks up my sleeve for some design ideas (clutch, waterpump, governor, ect)

[sandblaster]

 have some tricks up my sleeve for some design ideas (clutch, waterpump, governor, ect)....

Can't wait 

[jBernard]

what about some clarification..... 

-side cover with waterpump and governor deleted. also will incorporate removable clutch cover.

-electric waterpump

-servo driven KIPS

stay tuned!

[sandblaster]

This should be good!

[bakes1983]

G'day guys I am in the process of doing the conversion. Was wondering if anyone could tell me the degree u set the motor to? I was thinkin if this was wrong it would throw the handling right out the window. I could be wrong though. Thanks.

[jBernard]

the lower the engine, the better it will handle. i made my engine mounts with just enough clearance for the engine bolt to be able to get a socket on the end.
the FMF ktm/kx5 that was in the magazine, they recessed the engine mounts in the actual lower frame rail. they had the benefit of working with steel, but it looked like sh*t fab wise. no idea how much of a difference it actually made in the long run though. and no idea where they got that idea as i havent seen it done on any other bike.
I also tilted my engine back enough to be able to get access to the kips plate on the front above the exhaust manifold so i could service without having to take the engine out.

[bakes1983]

Thanks For your reply that's Interesting them cuttin into the frame, bugger that. I will try keep the 500 as low as possible to try help handling as much as I can. Would a 450 swingarm help u think? Just being that tad bit longer. Is yours a 250f frame?

[jBernard]

a 450 frame will have a bit more room in the engin ebay, as well as the swingarm being a tad longer. i dont think much though, just a few mm if i remember correctly.

yes mine is a 250f. i got a great deal on the bike to start with, 450f's were about 1500$ more than what i gave for mine.

[bakes1983]

And your 250f frame handles the power and suspension still works ok? I was also lucky I picked my 09 250f up for 1700 with Suposably a blown motor but all it needed was a cam chain and re timed. Then it run a treat. Sold that motor now and the 500 is going in