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Author Topic: The first in Greece  (Read 12847 times)

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Offline nikanor

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The first in Greece
« on: December 07, 2011, 05:36:41 AM »
As the title says, i believe is the first KX500AF in Greece.

A year ago i decided to have a 500cc and keep it forever, it was easy to choose between the CR and the KX cause someone said "f@@k honda the kawi is a beast" and that was it, i start looking for a K5.
I blame you guys and at the same time i really thank you cause i found the AF conversion amazing.
An alou frame for great handling,better suspensions, brakes etc.
But mostly i thank you all for all that infos i have found on this great forum.
Before i start posting some pics i really want to thank some people who help me alot and without them nothing would have happened.
So, many thanks to Kostas Boutos and Chris Fragos from the Boutos R&D Workshop and Dimitris Keramidas from DKracing.
Please it is NOT an advertising.

I have allready introduse my self.
My name is Nikanor i am from Greece Athens and that is my black beauty.


PS. sorry for my English.

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Offline nikanor

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Re: The first in Greece
« Reply #1 on: December 07, 2011, 05:57:01 AM »
What you are about to see it is made piece by piece and most of the parts come from the US and UK.
The engine is a K5 2001 and it came with electronis and carb. I took it apart and replaced a few parts and now its like new.
The rest of the bike is a KX450F 2006 that i put it together piece by piece.
God blass e-Bay.
I choose the 450 cause it has more space for the engine.
The bike has cost so far 5000? including shipping cost and custom services.

CHAPTER 1
"What we have here?"
When we first put the engine on the frame we notice that we are not going to have any problem with the sprockets and the chain, but we have some issues with the swingarm.
The swingarm it is not from the same bike (frame) even if it is a 2006 year, so we had to make new spacers from an T8 alou.
For those who use their own bike as a donor will not have any problem.





 
« Last Edit: December 07, 2011, 06:40:55 AM by nikanor »
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Offline nikanor

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Re: The first in Greece
« Reply #2 on: December 07, 2011, 06:46:06 AM »
CHAPTER 2 "Air box filter"

I use a kx250 98-02 air boot with an alou spacer that we all know by now



















As you can see it works just fine


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Offline kxpegger

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Re: The first in Greece
« Reply #3 on: December 07, 2011, 01:27:53 PM »
Great post!

My SH had a clearance issue at the right top side of the airbox. One of the bolts they used rubbed a nice little groove on the top rear of the oil/nitrogen reservoir of the rear shock. They used a Honda CR250 airboot though. You may not have this issue using the KX250 airboot. Mine only rubbed at near full compression.
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North Las Vegas

"05" RMZ450, "08" KX500AF "11" KTM 450SX-F "12" KTM 250SX "15" KTM450SX-F

Offline nikanor

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Re: The first in Greece
« Reply #4 on: December 09, 2011, 08:19:57 AM »
CHAPTER 3 "Y section"

Jfab's frame rails is a very nice solution but i didnot had the time to wait for the rails to arrive so i continued by removing the y section. After spending an hour to clean it was time to remove the holes.







You already have the engine on the right position so you know where to cut the main tube to make room for the exchaust pipe.
Make sure to cut the frame rails when removing the y section high enough after the angle.



If you decide to go this way i suggest to make this little pieces of alou and insert it to frame rail but dont forget to drill a hole so the hot air during the weld to be able to defused inside the rails and leave from the small hoses that the frame has.



The thicker point is for two reasons a) you know where to stop when you insert it inside the rail and b) it melts when you weld it.
Find some square alou tube T6 and cut the pieces you need.





Now take it to welder








Ok? You have it back?
Start triming it now for better look.





See you tomorrow

« Last Edit: December 09, 2011, 08:26:34 AM by nikanor »
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Offline azracer19

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Re: The first in Greece
« Reply #5 on: December 20, 2011, 09:14:49 AM »
thanks for the great idea... did you have the inserts milled? to fit?
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Offline nikanor

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Re: The first in Greece
« Reply #6 on: December 27, 2011, 04:25:34 AM »
Yes, but not to much, you want them to be a little bit tight.

I am having some issues with the server, it wont let me to upload pictures or i make a mistakes
I get a 404 server not found message, something like that everytime i click post or preview
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Offline nikanor

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Re: The first in Greece
« Reply #7 on: January 29, 2012, 12:40:56 AM »
« Last Edit: January 29, 2012, 01:59:23 AM by Motorrad »
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Offline nikanor

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Re: The first in Greece
« Reply #8 on: January 29, 2012, 12:43:42 AM »
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Offline Brute

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Re: The first in Greece
« Reply #9 on: January 29, 2012, 03:03:45 AM »
Fun project. Has to be a bugger getting parts! My Grandfather was Greek. Some of the family have made the trip there to see the area where he lived. Best of luck on the project!
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Offline nikanor

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Re: The first in Greece
« Reply #10 on: January 31, 2012, 04:12:14 AM »
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Offline Brute

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Re: The first in Greece
« Reply #11 on: January 31, 2012, 11:41:50 AM »
Nice looking brackets! Were they bent, welded, or machined? Still have parts coming for my mostly stock KX5. Weather cleared up a bit today in Washington State. Made me want to get one of the other bikes out for a ride!
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Offline nikanor

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Re: The first in Greece
« Reply #12 on: February 01, 2012, 07:04:40 AM »
Radiators

I bought the stock radiators but i used only the right one (clutch side), for the left side i use one from a YZ85 '00-'02.
The left one is to long and you will have issues with the pipe
I also used silicone hoses from samco.
We cut and rotate a few bends as you can see on the pics.

[img=http://img52.imageshack.us/img52/4378/img00546201106181407.th.jpg]

[img=http://img267.imageshack.us/img267/5854/img00545201106181406.th.jpg]


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Offline nikanor

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Re: The first in Greece
« Reply #13 on: February 02, 2012, 06:21:17 AM »
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Offline kxpegger

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Re: The first in Greece
« Reply #14 on: February 02, 2012, 11:44:17 AM »
Looks like you're close to the finish line! We're going to need a ride report soon! 8-)
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North Las Vegas

"05" RMZ450, "08" KX500AF "11" KTM 450SX-F "12" KTM 250SX "15" KTM450SX-F
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