k5 klx 450r conversion

[kawiboy63]

has anybody built a klx450r/kx 500 yet? it would be so sick if i could find a roller id build it with the enduro set up and headlight and all

[Twosmokerfan]

Hi Kawiboy63,

I am in the process of doing it now.  I am just sourcing the KLX and then will do the engine swap.  Have the donor engine, and done a lot of research on the electrical system, as I still want to keep it street legal.  Just re-built the K5 engine and tuning it now.  You will have to watch this space, and I will document everything for all to read when I have finished.

[Twosmokerfan]

Well, I just picked up my 2008 KLX450 and took it for a ride.  Awesome bike and I am really looking forward to the conversion.  Turn really nicely, but the suspension is where it needs work.

Looks like the only issue I will have is the electrical system, but I will let everyone know how it goes.

[weymouth399]

Any update on this project?

Bob W

[Twosmokerfan]

Update as follows:

Engine finished with new ignition (Powerdynamo).
KLX chassis being stripped and cleaned.
Brackets being welded in the next few weeks. 

It has been taking forever due to lack of time (haven't even had time to ride my Gas Gas EC300, although I did trial fit up the engine in the frame and it fits quite well, to the point where I almost decided to use the Gas Gas Chassis).

Electrics being finalised now while I am waiting for the chassis to be finished.

Sorry about the delay guys.  Kids and University study take up a lot of time.
TSF

[Twosmokerfan]

Update:
Chassis stripped and cleaned. Off to the fabricator this weekend.
Service Honda exhaust and muffler, along with hose kit has arrived.  Very nice I must say. I chose the Q series spark arrestor so as not to attract attention on the road.
I am taking lots of pics, and will figure out the attachment process when I get a chance.

Interestingly, the KLX looks like it doesn't need any radiator modifications. Just swapping of the hoses around and using the T piece and Y piece to have the water come up on the left hand side (as the KLX has it on the right).

Electrics are being modified while the chassis is away.  Most of the wiring loom looks like it will stay to keep all the horn, indicators, headlight and switches.  It will be ready for the electric start on the KX engine when I get the chance to look and design something (have to calm the wife down first)

Thanks for everyone's help so far on this site. You guys (and girls) are the best.
TSF

[royceymon@hotmail.co.uk]

if anyone is interseted and in the uk ,when i was looking for a donor chassis for my jan de groot motor corby kawasaki in the uk had a klx 450 rolloing chassis ,not sure if they still have it though!!!

[Twosmokerfan]

Hi everyone,

I have bee busy over the past few weekends and now have some pics to show.  Everything is now tacked in place and all brackets made.

All aligned and I will be welding it up in the next few weeks.  I can't wait.
The airbox is 90% finished using a 89 KX250 air box boot.  Lines up pretty nicely.
This was the starting point


I used the original KLX lower engine brackets using 2 spacers from the KLX front engine brackets.


Interestingly, the KLX engine weighed in at 33kgs, and the KX500 weighed in at 27Kgs.


Muffler and Bracket



Clearance of the SH Pipe and dummy fitup




Top view and the MZB ingnition.  I am lucky with this as the CDI and coil are in one unit. Meaning that I only have to find a place to mount the one item and not two.


More pics to follow.

[alward25]

Looking good

[kwakman]

good work TSF, I've just moved so after decorating I can go beserk as for the first time in 6 years I have somewhere indoors thats warm to work in where wifey can't moan.result! K.

[royceymon@hotmail.co.uk]

looking sweet !!!

[Twosmokerfan]

Pics from today:

Front with brackets for front engine mount


RHS of frame with the inserts


Inside airbox with adaptor plate for 89 KX250 air boot.  Needs no spacer plate and clears the shock except the very top, but I should be able to adjust it to not touch.


Carb alignment with air boot


Close up of frame mods and clearance to Power valve cover.


Well, I now am playing with the electrics and have to find a spot to mount the ignition (not a problem), along with figuring out how to trick the main relay into thinking it is still a 450.

The frame is being welded up this weekend on Sunday, and then the final assembly begins......

TSF

[weymouth399]

Very nice, this is what I need to do to mine.

Bob W

[Kiwi500]

Looking good TSF, how did you find plumbing up the ignition??
I'm still sitting on my ass, yet to get a frame, but we are keeping an eye out.
Haven't even had a ride since mid Jan, just to busy with work and family !!
Will keep an eye out for more pics.
Cheers
Grant

[Twosmokerfan]

Hi Grant,

That KLX frame I spoke to you about is still here and for sale if you want it.

The electrical system doesn't seem to be too hard at the moment.  Your do need the MZB ignition to run all the KLX extras and the 55/60 watt headlight and all the road gear.  I am keeping the battery for the moment, and the MZB (as you know) comes with the reg/rect and that will be hooked directly up to the battery.

The KLX runs a main relay that closes once the engine is running, and I will need to trick that relay, as i don't won't the full power going through the key ignition as my guess is it will toast it.

I am keeping track of the project and will do a write up for those that wish to convert a KLX with the KX5 engine.  This will include the electrial mods.

TSF