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Author Topic: Project bike  (Read 9448 times)
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Flyin Hawaiian
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« on: April 06, 2009, 05:36:27 AM »

Here are a few pics of my newest project. Its a 2002 KX500 engine in a 2004 KX250 chassis.
Before

After

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LWC3077
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« Reply #1 on: April 06, 2009, 10:44:29 PM »

whats the advantage over the STD 500 chassis? i dont know much about these bikes other than that the 500 motor was an awesome sidecar cross motor for many years.
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Flyin Hawaiian
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« Reply #2 on: April 07, 2009, 07:01:53 AM »

Much better handling. The last version of the 500 came out in 88, in 89 they got a 3rd powervalve and some suspension upgrades, 43mm to 46mm forks. Over the years the engine remained untouched except for some jetting changes. They did get upside down forks and a few more suspension upgrades but remained pretty much the same up to its last year of production which was 2004. The reason for me doing the conversion is because at my last enduro, I somehow ended up spinning a main bearing in the case. So I was faced with either buying new cases, finding a competent machine shop to fix my cases or doing what I had planned to do a little earlier than I had expected. Which is the conversion. I have most everything that is needed except for a exhaust system, which is available from Service Honda, they build the aluminum framed CR500 and KX500. It will probably be a bit much in the tight woods though!
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« Reply #3 on: April 07, 2009, 11:15:40 PM »

i admire guys like Larry Roesler and Paul Krause who could ride these things flat out for extended periods of time in the Baja 1000
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Flyin Hawaiian
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« Reply #4 on: April 09, 2009, 12:15:58 PM »

With good throttle and clutch control, 500s can be ridden effectively almost anywhere. They are actually quite smooth in the way they deliver power. I think that alot of people that jump on to a 500, twist the throttle like they are on a 125 or 250 and hurt or scare themselves into thinking that they are unrideable beasts. I met Larry Roesler once at the Blackwater 100, super nice guy! Grin
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« Reply #5 on: April 09, 2009, 05:37:38 PM »

i have a video of the 85 Baja 1000 where Larry rode with Kurt Pfeiffer on a 510 husky and did win but then not long after the race end, were penalised for riding with out lights turned on at one stage or something. That was before he got onto the KX500's
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maicoman
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« Reply #6 on: April 15, 2009, 08:49:04 AM »

Awesome bike FH. I do have a soft spot for the ole KDX. It's on my list of bikes to get. I totally agree with your approach to riding a 500. My Maico SC490 is like a armchair to ride. The power is there if you need it but it all depends on how much you want to give it. Sure it can get violent but sometimes that's half the fun. Smiley
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Flyin Hawaiian
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« Reply #7 on: May 05, 2009, 02:23:28 PM »

Ive been making some progress with the 250/500 hybrid. I was going to give my swing arm to a machinist friend to have it modified to fit in between the cases and the frame but I got impatient and decided to tackle it myself. With a cut off wheel and a hack saw, that had a dull blade, I was able to make the necessary modifications to the swing arm. It came out much better than I thought it would and allowed me to fit the whole rear end onto the frame. Now I have to mod the airbox to accept the 500 airbox boot and the rear half will be done.
Heres a few pics.
Swingarm mounted.

Shortened and redrilled headstay.

Carb fitment, have to use a 03/04 KX250 intake manifold to clear the shock, 500 intake put the carb too close to the shock.

Stock 03/04 KX250 tank clearance, just makes it! Not sure what to do about extra fuel, an IMS or Clarke will no longer fit. May have a custom carbon fiber or aluminum tank made for it.


Ill post more as the project progresses. My next project will be a KDX200/220 engine into a 03 up KX125 chassis. Im really enjoying this project!
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Mick
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« Reply #8 on: July 18, 2009, 03:07:05 AM »

Just wondering how this project is going ??

Cheers Mick.
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Your a long time dead, so get out there and enjoy yourself while you still can :-) would loved to have been able to race vintage enduro bikes in Victoria, but sadly that as yet has not happened, so many blokes would have loved to be able to race, owell shit loads of us still have the memory's of racing enduro bikes back in the late 70's and 80's, time to move on to other things I guess :-) but if racing classes for vinduro bikes start then I will dust off my bike and be out there racing my old bike as that is what it was made for ( Racing )
Flyin Hawaiian
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« Reply #9 on: August 04, 2009, 12:29:29 PM »

Stalled at the moment, my fiance lost her job, thanks to the spiraling economy, and we had to tighten up the purse straps for a while. She found another job that pays better, less hours and better benefits so now we are starting to get back on our feet and the 500 project will start up in a bit. i just need to buy a pipe for it to be able to advance to the final stages. I have to thin the herd a little and am going to sell my 02 YZ426, I havent ridden it in 3 years so it must go.
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