Posts
3538
Joined
4/15/2013
Location
Suffolk, VA
US
Fantasy
2006th
Markee
10/1/2017 6:07am
10/1/2017 6:07am
Edited Date/Time
3/13/2019 8:53am
Well, here it is. Next project bike. Been looking for a 500 for a year. Just couldn't get the timing right or one of two things; 1. Its mint and want 5k plus or 2. Roached out sand drag POS that they think is worth mint money.
This pops up the other day on CL 30min from me. Motor has been completely gone through so I have a BIG head start.
I ride 250 smokers. Built 300s. But one ride around the yard and im wondering what I have got myself into, unreal.
The goal is to update the brakes, wheels, suspension, clutch and all around fit and finish.
This pops up the other day on CL 30min from me. Motor has been completely gone through so I have a BIG head start.
I ride 250 smokers. Built 300s. But one ride around the yard and im wondering what I have got myself into, unreal.
The goal is to update the brakes, wheels, suspension, clutch and all around fit and finish.
The Shop
Most of my time has been figuring out the brakes and forks. I'm pretty much done. I need to move the brake stop and weld in the new rear brake master cylinder. If you look close, you can figure out what wheels i'm using for the upgrade.
The 2011 Kawi triple trees got the stem pressed out and the KX500 stem pressed in. The bottom diameters were a difference of .006 thousands the wrong way. Meaning I had to "add" .006 to the 500 stem. How do you do that? Well Knurling a shaft increases the diameter but the contacting surface area is decreased.
Thats what I did. Knurled until I had a interference fit that was on the extreme side. Heated tree and froze stem in CO2 for 6 hours. Light coat of epoxy on the tree and dropped the stem in with the help of a 100 ton press. Done.
On the top tree, the difference of the stems were very little. But I machined a bushing/washer to make up the difference. Pretty delicate part to make right.
And... Clean slate.
Working back to the front on this Brembo brake conversion. Old tab removed.
Next. Going to make new rear master cylinder mount, and new peg mounts right and left. Also the brake pivot was so worn I just cut it off, i'll make a new one.
Got to weld in a better (maybe adjustable) fork stop.
New fork stop made.
Welded in place.
Time for lunch!
Break time before I move to the shifter side.
I've been paid a lot to help others finish their projects/goals with countless motorcycles. It was really refreshing being on the other end having Larry Wiechman, clean up and installed a compression release. Bad ass work!
Pit Row
do you use a ktm caliper?
which brakerotor?
I make the conversion with a rmz450 brake and kx450 wheels
I'm never ever putting to much work into any sub frame, function over fashion here.
If you don't mind me asking...
I have a 2005 KX250 (steel frame also) that needs a new steering stop put on. I am not a welder, but can you explain how you welded the new homemade steering stop onto the frame? I intend to get a friend who can weld some to do it. Some previous owner wrecked it and put on some "not 100% satisfactory" looking steering stop.
Thank you.
The main concern is warping the head tube. So if you have a friend that can TIG or MIG weld, that's what I recommend (TIG proffered).
I used 1/4 thick steel. Radius the back side of the stop to it fits the headtube good. Be sure to have your tank, radiators etc. on so you can test the stop before completely welding it on.
I have a piece of 4130 that is 1/4" thick.
I did intend to radius it to the head tube.
It is on a 2005 KX250. It's a second bike, as I have my main 2005 KX250. Based on your advice, I will do some A-B comparisons to try to get the second one the same as the first one with the test fitting.
Thank you for the tips.
To the OP, is that a factory pipe? I noticed the gold colored welds.
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