'09 500AF build

[jBernard]

i dont think the geometry of the 250 and 450 are that different. i know the swingarm is .750" longer.
mines not to the riding stage yet.
stock suspension is out and i've got Showa A Kit going back in.

[jBernard]

trying to make some progress on this thing!
Suspension back next week, will post some pics of that, will look badass!

Head/Cylinder is at Tom Morgan Racing and will be back around a week or so.

Split cases tonite and going to go thru and vaporblast the cases so shes looking brand new.

here's a pic until the next update:

[jBernard]

Tom Morgan Racing High compression head, ported cylinder for MX, and a windowed new weisco piston from Todd

[sandblaster]

Nice, can you post a pic of the bottom of the cylinder?

[jBernard]

sure, heres a quick iphone pic.

larger res:
http://oi44.tinypic.com/2liivmd.jpg

[jBernard]

wow. time is flying and i'm dragging on this thing  
I've only got a few more bearings to pull out of the cases, then they go out to get media blasted then i can start putting engine back together after that.

But for now here's some pics of parts that are going to be going back on.

Showa A-Kit from 06/07 ProCircuit Team bike (no production serials on lugs)
WP Micro Fork bleeders


TC Racing CNC'd hubs, laced to bulldog stainless spokes, and SM Pro Platinum matte black rims
Tires are Michelin MS3 Starcross  80/100/21 on the front
and Bridgestone M204  120/80/19 on the rear


Galfer Tsunami 270mm Oversized Superlight (aluminum spider) floating rotor


Galfer Wave Rear rotor


Ironman 47T sprocket with J27 Titanium socket head bolts and aluminum nuts


hopefully more pics of things getting done soon. stay tuned!

[jBernard]

and thats my new '14 KTM 250SX in the background. it is.....AMAZING. and after having my first Brembo brake and hyd clutch experience, i WILL be retrofitting a brembo front caliper and master cylinder on my 500AF. i have to build a oversized bracket anyway, to fit the 270mm rotor, so might as well make one for the brembo caliper at same time.
I dont think i'll be doing Brembo on the rear though, i'm not that fast of a rider to really feel the difference on the rear between the brembo and the nissin as of now. + the rear bracket is more involved and harder to design than the front.

also going to attempt to do a REAL hydraulic clutch on this engine as well. Ive seen a few pics of a French guy on here show his off, but not give any details on how he did it. So this may take some time. and figuring out the location perfectly as well as the pushrod length needs to be precision made, this will take some work.

[kxpegger]

and thats my new '14 KTM 250SX in the background. it is.....AMAZING. and after having my first Brembo brake and hyd clutch experience, i WILL be retrofitting a brembo front caliper and master cylinder on my 500AF. i have to build a oversized bracket anyway, to fit the 270mm rotor, so might as well make one for the brembo caliper at same time.
I dont think i'll be doing Brembo on the rear though, i'm not that fast of a rider to really feel the difference on the rear between the brembo and the nissin as of now. + the rear bracket is more involved and harder to design than the front.

also going to attempt to do a REAL hydraulic clutch on this engine as well. Ive seen a few pics of a French guy on here show his off, but not give any details on how he did it. So this may take some time. and figuring out the location perfectly as well as the pushrod length needs to be precision made, this will take some work.

My 2012 KTM 250SX is a great machine and makes just under 50 HP according to MXA magazine. One of the best machines I've owned to date! That 500 of yours is coming along nice! Waiting to see the finished product and a ride report!

[jBernard]

thanks! i need some deadlines to put on myself so i have some accountability,

this is my first ktm. i grew up on CR 125's, then got out of mx when i went to college. this is my first bike back into mx (im 30), i'm 6'4" and about 240# and the ktm puts a smile on my face EVERY time i ride it so far (5 times thus far). there have been several 'oh s**t!' moments on her so far, i cant believe how hard this bike pulls even with me on it. for a kid to get off a 125 and get on this and weigh say 160# would be like a rocket ship! easily the most powerful, best handling, best feel, braking, powerband, bike i have ever ridden. cant say good enough things about it.

saying that, if i find the 250sx fast, i think a high compression MX kx500 is going to be terrifying.  

[jBernard]

looks like i'll be the first to try this out! should be interesting.

[jBernard]

well shizzzz. trying to pop that rubber outer seal out looks like i slipped and got into the seal surface with a flathead.   bonehead move.
by the looks of it how do you guys think i should fix this? leave it as is? ghetto jb weld and smooth it out with my finger?

[ylwgtr]

ive been there before.....just put a smear of black three bond on the seal and it will be ok  
i was contemplating using one of those harley decomps aswell!

[ylwgtr]

dont forget to kiss it with some sandpaper to take off the high points

[kxpegger]

Yamabond or some other semi-hardening sealant.

[jBernard]

thanks guys, will do.
and nice eye ylwgtr!!! impressive you knew what it was from.