2000 kx250/k5 conversion

[kranker1450]

thanks guys. I love the natural pipes so much more than the chrome ones. They are more work but in my opinion they look much better. I am a fan of the old school works bikes with the hand made pipes. That is the look I am going after. That is why I went with the gold rims to plus everyone has black ones. lol Sandblaster is a great guy and awesome too deal with. I also have to give props to alward25 for the killer price and service on the warp9 wheels. They are so sick! I can not wait to et them on!

[kranker1450]

I have a couple questions on the 99-02 conversions. First, when fitting the crossover hose from the radiator to radiator I know you grind down the pinch weld to gain room. I was wondering if anyone wished they would have notched the frame slightly to gain more room? Here is a pic of the area I am talking about. The area I am talking about is marked "smooth" in the pic.



The next question is for anyone who has used the JFab headstay kit. When putting it on I can not figure out anyway to get this thing to line up. It is a 2000 kx250 frame with a 90 k5 motor. It looks to be way off or I am really missing something easy. Here is a pic of what I am talking about. You can see the bracket actually touches the headstay mount on the bottom. This is after flipping the bracket upside down to gain the extra room. Also the piece sitting on the bracket in the fore ground is the rest of the bracket kit that is needed to be welded on to mount to the bracket. There are 2 of these pieces. I must be really missing something. I have asked JFab to take a look at the pics to help me out. I would like to say that I am in no way bashing the quality or workmanship of this kit. I am missing something and just put this out here for help nothing more. I think this is a quality kit and I am very happy with the purchase.



Here is a pick of the over all motor in the chassis so you can get an idea of how it is setting. It is bolted through the swing arm and the lower mount lined right up. It has a bolt through it and the front mount has been cut off and tack welded in the current location to work with the rest of them. Thanks for looking.

[motopunk]

the j-fab headstay kit is a cool thing...  but you have to make your own brackets. the kx250 headstay-brackets could not used or modified to the kx500 engine. the k5 engine sits closer to the mounts in the frame.

which radiators do you want to use? the stock 250-rads would work with only cutting the tube to the right length, that goes to the cylinder on the left side .
 you should contact   don46  . he had made several of this 99-2002 frame conversions..  maybe he could help you a little bit forward...

[kranker1450]

Just spoke to JFab. He cleared everything up. Great guy. As i thought and as Motopunk said i need to make my own bracket. No biggie, just thought i was missing something else.

Moto: I am planning on using the 250 rads. They will fit with just the grinding of the pinch weld with a little clearance. Was just curious if anyone wish they would have notched the frame afterwords for more clearance. Figured now is the time instead of later.

Thanks

[motopunk]

Just spoke to JFab. He cleared everything up. Great guy. As i thought and as Motopunk said i need to make my own bracket. No biggie, just thought i was missing something else.

Moto: I am planning on using the 250 rads. They will fit with just the grinding of the pinch weld with a little clearance. Was just curious if anyone wish they would have notched the frame afterwords for more clearance. Figured now is the time instead of later.

Thanks

how was the fitting before with the 250 engine? i do not understand the reason for grinding on the frame, because this are the rads, made for this frame.. 
mounting with washers to get the rads a little bit away from the frame is in my eyes a better option. 2. option : cut off the rad mounts and lift the rads up u little bit , but watch out, that the fork legs couldnīt touch them by full turn of the handlebar.


i have an 86 k5 engine in a 93 250 frame with k5 rads..because the bike is completely assembled from used ebay-parts and new spareparts. so i could do it without any modifying to the 90-93 paralell cooling system. the k5-rads did also fit perfectly to the 93 kx250 frame. all i had to do was made little brackets to get them a little bit forward on the upper side to find the clearance for the big crosstube between tank and frame.

[kranker1450]

moto: With the k5 motor the gap between the cylinder is greatly reduced. If the weld is not ground down I am afraid that the hose would chaff and eventually wear a hole in it. I will be moving the lower rad mount forward slightly to gain some clearance for the hose to cylinder which will push it into the weld on the front. This is why I need to remove the seem. Hope that makes sense. With the 250 motor in it there is plenty of room between the head and the frame for the hose to have ample clearance.

Thanks Tom

[motopunk]

moto: With the k5 motor the gap between the cylinder is greatly reduced. If the weld is not ground down I am afraid that the hose would chaff and eventually wear a hole in it. I will be moving the lower rad mount forward slightly to gain some clearance for the hose to cylinder which will push it into the weld on the front. This is why I need to remove the seem. Hope that makes sense. With the 250 motor in it there is plenty of room between the head and the frame for the hose to have ample clearance.

Thanks Tom

ok.. now i see what your thinking is ... some times its hard only imagine some things without seeing the parts directly... 

[kranker1450]

ok, it has been awhile and I do have some progress on the 500. I have got the pipe all modified and mounted to the bike. I have also got all of the mounts tacked in for the pipe. Got the headstay removed from the stock head. here is a pic of the pipe mounted on the bike and the silencer in its final position.

[sandblaster]

Lookin real good.
Thanks for the update..

[don46]

I smoothed the area for the hose and put another piece of rubber in fact I think it was a heavy duty heat shrink  in the area that rubbed to pervent wear. I too like the "works" pipe look. always used those on our race bikes as well, wd-40 after every wash and if they looke a little ratty a little naval jelly and back to the works look. I really liked the 99-02 conversion it was by far the easiest to do and the frames are plentiful. I think the only difficult part was the tank, warming and reshaping to clear everything. looks good

[kranker1450]

Thanks Blaster and Don. I have always used wd40 and a scotchbrite pad in the past with good results. Hopefully I will get a little farther on it this weekend. I had to indent the pipe a little more than i wanted to so it would "fit" like i wanted to. I spoke to a good friend about it and he assured me that i probably wouldn't even notice the difference in power and just laughed.

[kranker1450]

I got the frame off to powder coat. should have it back tomorrow. will start putting it all together. I will get some more pics for you then. Here is a pic of the wheels ready to be put on. Thanks for looking.

[kranker1450]

I got the Parts back from powder coat. Assembly has begun! I am pleased with the powdercoat, i think it turned out well. Here is a pic of the frame. Sitting on the table you can also see the dog bones,axle blocks and part of the triple trees. And yes the nasty hose on the on the side of the head will be replaced with a new blue silicon one. lol..Thanks!

[Foxx4Beaver]

that's gonna look awesome with the gold wheels and black frame.

[kranker1450]

Thanks Foxx! I am slowly getting it put back together. here is the latest.




I do have a question for those that have done this conversion before. What did you do about the throttle cable routing out of the top of the carb? just heat and remold the tank? I thought I read something about a 125 carb top? here is a pick of  what I am talking about.



Thanks again!