KX Guru Racing

So, you remember this guy? http://i644.photobucket.com/albums/uu165/oemcycle/KX500AF%20PROJECT/1-30-11/1.jpg Well after a visit with Mr, Sawzall and the grinder, it looks like this: http://i644.photobucket.com/albums/uu165/oemcycle/KX500AF%20PROJECT/1-30-11/DSCN0824.jpg http://i644.photobucket.com/a...

Since I had to cut some of the length off the new frame rails I used the scrap piece to test fit the new rails. To make it fit smooth and clean I filed two of the four corners from the test piece so that it would fit the radius of the frame guide: http://i644.photobucket.com/albums/uu165/oemcycle/KX...

You can make your own frame rails but I ordered a set from JFABMOTORSPORTS 2880 Jackson Rd Wentzville, MO 63385 U.S.A. jerrysfab@centurytel.net Jerry requests you contact him Via Phone at the shop to discuss any services 636-673-7102 If you are going to use these frame rails from JFABMOTORSPORTS ord...

My next step was figuring out how to mount the lower frame rails to the lower frame. Keep in mind that I am not a metal worker :roll: This is where I was at: http://i644.photobucket.com/albums/uu165/oemcycle/SHOP/1-27-11/123.jpg Both sides had the frame rails cut but I needed to remove the inner fra...

The clutch cover fits perfectly without machining it. Grinding the swing arm was all that was required. http://i644.photobucket.com/albums/uu165/oemcycle/KX500AF%20PROJECT/1-15-11/DSCN9475.jpg http://i644.photobucket.com/albums/uu165/oemcycle/KX500AF%20PROJECT/1-15-11/DSCN9479.jpg http://i644.photob...

Here you can see the raised part of the swing arm that is preventing the clutch cover from bolting on. http://i644.photobucket.com/albums/uu165/oemcycle/KX500AF%20PROJECT/1-15-11/DSCN9473.jpg Just a minute or two with a hand grinder and sander. http://i644.photobucket.com/albums/uu165/oemcycle/KX500...

This is what happens on a four year old MX bike that has not had the bearings lubricated. http://i644.photobucket.com/albums/uu165/oemcycle/KX500AF%20PROJECT/1-15-11/DSCN9466.jpg I was going to replace them anyway but I figured I'd show those non believers what happens with even relatively new bikes...

That part of the swing arm actually has a raised embossed area that is making it a close fit. I believe I can machine the swing arm about .015" deep by about .25" wide and it will be fine. I may also have to machine a bit of the clutch cover as shown below. http://i644.photobucket.com/albums/uu165/o...

Found a nice crack in my clutch cover... Time to go see Mr. Tig http://i644.photobucket.com/albums/uu165/oemcycle/KX500AF%20PROJECT/1-15-11/DSCN9471.jpg What I'm doing next is checking the clearance between the right engine case and the swing arm. I have the frame, swing arm, and engine bolted toget...

Just for grins I went to mount the Swing arm to the engine and frame. Guess what? It does not fit. The engine cases measured 94.3MM or 3.713". http://i644.photobucket.com/albums/uu165/oemcycle/KX250F%202007%20PROJECT/1-12-11/ENGINECASES.jpg The inside to the inside of the swing arm bushings when pus...