K5 Rebirth

[Suva]

Thanks gents!  Somehow didn't even think about actually pressing them out Duh...  I've a small vise in the garage, will give it a shot tomorrow.

[sandblaster]

Oh yes, I've done them in a vice as well, just be sure you use the right size sockets for both ends as aluminum will dent easily...

[Suva]

Front motor mounts are welded in Wound up making it down to dad's shop the other day and fab'ed up a headstay.   Including randomly bsing with friends/fam and scrapping the first couple tries, took a better part of the day an still not totally thrilled with the result.  Should (hopefully) work though.
Monkeyed around with mocking up the pipe while I was at it... Looks like it'll be quite the chore.  Where is everyone getting those green radiator hoses to flip the inlet for better clearance?
No pictures-camera battery is dead an misplaced the charger in my recent move...

[Suva]

In the interest of fitting a larger capacity tank, I read in a post ( http://www.kxriders.com/forums/index.php/topic,8211.0.html ) that Flying Hawaiian used a 05-07 tank for better fitment on his '04.  KXer asked how well it might fit on a 01, but F.H. didn't know... Anyone ever try mocking one up?  Seems like there are very few Kx's in my neck of the woods to compare with- weapon of choice tend to be Katooms and YZs with some CRs.  If no one knows an I can't find anything to check against, might go ahead and order one with the hopes of returning it if it's a complete no-go.  Would really rather not order blindly though. 
Sounds like the clark has the hands up vise IMS, anyone have a differing opinion?

[Suva]

Finally getting some progress going again...  Frame is powder coated, lookin pretty good.  After struggling quite a while with c-clamps, a vise etc on the linkage bearings and getting nowhere, I located a press.  Took quite a bit of force to get them to initially pop. 
For lack of info, other than that the frame was changed in '03, will just plan on using a aux tank for now.  Maybe look back into it later on.
Starting my 4 off tomorrow morn an hoping to have most of the parts together by the end of the day.  Have to run to CD'A, then wire in a 230 outlet in the garage though, so we'll see.
Key things yet to accomplish:
    -dent tank
    -finish pipe
    -fab pipe/silencer mounts
New plastics will come later down the road
My FMF TCII came in the mail, seems cutting an inch or so off the back would help line up the rear mount better + protect it a touch more.  Was considering removing the front mount, but not sure using just one is such a hot idea.  I am positive I'll be testing it's strength on a routine basis (aka, bouncing off trees, terra firma)
hopefully pics tomorrow...

[Suva]

So much for keeping up with this...

I've had the bike running for a bit now.  been hard to get around to posting pics as I don't have internet at home anymore...

Wound up using an FMF pipe from Service Honda (Thanks a ton AJ!!!) as every time I touched the DEP pipe in one place, it screwed up what I did somewhere else (very thin compared to the FMF).  I also tend towards the brute force methodology, so others might have better luck with it. Still have it though, might work on it more later to use as a spare.
Had to pick up some Yamaha(?) snowmobile exhaust springs as the ones I had were way too short.
The FMF only needed minor massaging to gain a little more room, and I did wrap the rad hose with some reflective tape as added insurance.  Also cut the front mount off and welded a 250 mount (mocked up better than the 500 mount) low on the chamber to match the frame mount location.

Used a new 250 clutch cable, and filed the lever a touch to give the cable a little play.  Works great!

The intake boot is still super close to the rear spring, which worries me.  Saw someone here mentioned a kdx 250 intake manifold helped him, so will try that.

There were a few other things I was going to mention, but they're skipping my mind at the moment...

Must say however, with this engine in a capable chassis it is a beautiful thing in the woods.  And yes, even and/or especially in the tight single track we have in the mountains of N. Idaho.  You HAVE to love that low end grunt!  Woo hoo!



 

[Suva]

Soooooo, after one layoff and two moves later....

remembered a couple things might help others along.

-the 90* coolant hose I used behind the exh. pipe is from the 250's head and trimmed to fit
-original exh springs were way too short, so went to my (then) near by ohv shop and found some that worked off of a yamaha rino (i think).  pretty tight still, but didn't find anything closer.

P.S.  after mocking everything up etc. etc., make SURE you lock-tite all of your engine mounts.  St. Anthony's got a little more iron somewhere out in her dunes...

[yeomans]

In the interest of fitting a larger capacity tank, I read in a post ( http://www.kxriders.com/forums/index.php/topic,8211.0.html ) that Flying Hawaiian used a 05-07 tank for better fitment on his '04.  KXer asked how well it might fit on a 01, but F.H. didn't know... Anyone ever try mocking one up?  Seems like there are very few Kx's in my neck of the woods to compare with- weapon of choice tend to be Katooms and YZs with some CRs.  If no one knows an I can't find anything to check against, might go ahead and order one with the hopes of returning it if it's a complete no-go.  Would really rather not order blindly though. 
Sounds like the clark has the hands up vise IMS, anyone have a differing opinion?

I chopped the oversize clarke tank for the 99-02 kx 250 up to accommodate the larger head of the 500.
Took the tank to a plastics guy in town. He determined what type of plastic the tank was manufactured from. He was able to weld a new piece on the bottom of the tank.
I would say I only lost about 1 to 1.5 litre capacity in doing this. Fits perfectly now.
If you'd like some pics for ideas, give me a shout.

[Suva]

NICE!!!  Now that I'm out in "desert(ish)" country and only hair & hound type races around, thought I was going to have to buy another 500 so I could get a big enough tank.  pictures would be awesome!

[yeomans]

Having some trouble posting photos now for some reason?

[sandblaster]

This site no longer can host pics.
You have to put them on photobucket, facebook, ect and then link them here..
See how here.
http://www.kxriders.com/forums/index.php/topic,10040.0.html

[yeomans]

[yeomans]

[yeomans]

[yeomans]

Just wanted to thank Sandblaster for photo tips. I'm pretty bad with computers, so I had to call in the girlfriend for help.

Suva,
First is the uncut tank, Notice how it won't even sit on the top of the frame rails. The masking tape and pencil was my imaginary line
Second is the tank after I got it back from the plastics guy. I was warned that it wasn't going to be a pretty job by any means, but this is what he was able to do for me, and for my situation I was happy with it. It holds.
Third is of finished tank sitting on the mock up build. I also sent my head to Larry for the decompression valve mod, and I got the stock motor mount chopped off, which is why it may look a little funny at the head.
Forth, my mock up build to date, just got the foot pegs and I'm waiting on my ignition from Alex at the moment.

If you need any other pics just ask. Now that I got it figured out.