KXF 250 2007 for KX500AF

[Dutch-K5 Fan]

Did the CR500 pipe need to be modified much to fit? Im on an extremely tight budget and may go this route on my project.
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Have made a new piece that goes into the cilinder and relocated the fist section.
And the end piece that goes into the mufler is shortend.
Making the Exhaust to fit is a pain inthe ass work to do. But it can be done.

Dutchie

[jfabmotorsports.com]

Thanks guys!!!! Had a lot of fun today!!!

My Exhaust is a new cr500 unit from RINO Racing. For what i've hurt they are made by SPES Exhaust. Used a Rino on my
Rmz250 and My brother has one on his RM125 and my uncle on his K5.

Dutchie

Did the CR500 pipe need to be modified much to fit? Im on an extremely tight budget and may go this route on my project.

Nice work Dutchie 

This is a FMF Fatty with very little tweeking.

[edgar_kx3]

Dutchie....There are many ways to "skin a cat" My way is most certainly one of the hardest, having to hunt the right tube and then bend it. In this photo, the solution is easy to see. Just add about 3 inches. I DID NOT HAVE ANYTHING TO DO WITH ANY WORK ON THIS FRAME No matter what path you take you still have to cut somewhere and then weld it back.

Alright! i have a question, i done my 500 kx similiar to this and i have cracked the frame in the added in pieces 3 times!!! i do race it, im not sure why it is not holding!! any advice??

[kxpegger]

Dutchie....There are many ways to "skin a cat" My way is most certainly one of the hardest, having to hunt the right tube and then bend it. In this photo, the solution is easy to see. Just add about 3 inches. I DID NOT HAVE ANYTHING TO DO WITH ANY WORK ON THIS FRAME No matter what path you take you still have to cut somewhere and then weld it back.

Alright! i have a question, i done my 500 kx similiar to this and i have cracked the frame in the added in pieces 3 times!!! i do race it, im not sure why it is not holding!! any advice??

Is it cracking at the welds or somewhere else?

[edgar_kx3]

either right above or below the weld! its either the alum is too soft or the weld i quess!

[dangerous dean]

without sounding silly but have you tried welding it with different grade ally? is it tigged or migged ? if its cracked either side it usually mean the ally has got to soft through heat from the welding try welding it up wet rags either side to stop heat dissipation

[edgar_kx3]

its tig welded. no i have not tried any other alum, but soon as i can get the old stuff cut out. think i gonna tried solid square stock, and mill it down on each end to fit inside the stock rails!. hope that works, if not i will replace the entire carriage!

[Dutch-K5 Fan]

its tig welded. no i have not tried any other alum, but soon as i can get the old stuff cut out. think i gonna tried solid square stock, and mill it down on each end to fit inside the stock rails!. hope that works, if not i will replace the entire carriage!

Thats what i've done with mine Y section. Then there's some material to weld with.

Dutchie

[kxpegger]

its tig welded. no i have not tried any other alum, but soon as i can get the old stuff cut out. think i gonna tried solid square stock, and mill it down on each end to fit inside the stock rails!. hope that works, if not i will replace the entire carriage!

Even with the same materials and filler rod welding aluminum is a little tricky. I used to be a certified stick welder back in the 70's before Mig/Tig welders were prevalent. We learned to weld aluminum with Oxy/Acetylene and it took a lot of practice not to produce a soft or brittle weld.

http://www.lincolnelectric.com/knowledge/articles/content/alum.asp

[jfabmotorsports.com]

I would replace the frame cradle with one peace units all the way to the down tube. Welding a peace in like that is the easy way out and should never had been done.  JFAB

[edgar_kx3]

jfab ive been lookin at yours and i like the cradle, can u bend me one?? if so how much would it cost?!?

[jfabmotorsports.com]

jfab ive been lookin at yours and i like the cradle, can u bend me one?? if so how much would it cost?!?

Yes I can. I have a few more orders to fill. I just got the material and plan to get to them Monday....so I plan.
$85.00 NO lugs or mounts included. Email me and let me know.  JFAB

[bob larry]

Amazing!!    I have a 06 kx250f frame sitting in my garage waiting for the lottery to pay for a new motor......hummmmmm

Way to go on your project!  Good job

[Dutch-K5 Fan]

Thanks Bob Larry. I haven't ridden the bike much.
It sure is a dream to ride. Feels nimble, quick steering, easy to move around the bike, and the best thing that
it feels much lighter than the old steel frame.

You also whant to put a kx500 engine in your frame or rebuilding your kxf250 engine?

Dutchie

[bob larry]

Thanks Bob Larry. I haven't ridden the bike much.
It sure is a dream to ride. Feels nimble, quick steering, easy to move around the bike, and the best thing that
it feels much lighter than the old steel frame.

You also whant to put a kx500 engine in your frame or rebuilding your kxf250 engine?

Dutchie

Yes, I think it is time.  With some help I think I can pull it off.
I had my 06 kx250f for sale with blown motor for a while now.
I picked up the 92 K500 in September.  Still riding it in November here in Niagara Canada! G warming?

The biggest pain looks to be the cutting of the frame.
The custome exhaust
And knowing where to line up the engine in the frame has got to be a $@#$

Getting the new frame pieces milled down and inserted into the frame seems to be the strongest way to go.

After 50 or so of these are built blueprints could be made for ALL the pieces needed.  Like motor mounts
and the frame pieces.  Or an entire new one piece frame would be dope.



 

Jfab you have a 250f framed 500 too?