DK 2007 kx250/500 sf

[splatter]

A little danish project here (sorry not the best English)
I got an old 1986 kx500 im going to put in to a 250 steelframe from 2007
any advice would be great

i startet drilling the pivot hole for mounting the engine on a 17mm pivot bolt.
Later when i get some wheels im going to cut the swingarm so it will mach the width of the engine-mount. and line up with the chain sprockets.

[sandblaster]

Welcome to the forum.
Can't wait to see your progress.
Post some pics so we can see how the Danish do it 
Sounds like you have the right approach.
Once you drop the engine in it becomes more clear what needs to be done.

[splatter]

trying to post some pictures but im havin a bit of a problem making it work hmm

[splatter]

cut this section away and weld in a "half pipe"


or cut in these places and move the "Y section" up and put in 2 peases of pipe making the cradle longer up tp the Y-section again

HAH finaly got it right with the pic´s
well these are my 2 ideas on cutting the frame to make room for the pipe

anyone have an advice or a better idea on this?

[zz3gmc]

It looks like you only need a little clearance for the pipe. Can you just trim the area at the base of the "Y" for the needed clearance? I would look into that before cutting and extending the cradle. While your at it kick the steering head angle out some to help with the problematic handling of the 05-07 KX250 steel frames. I know because I have one ! There is a thread here in the 250 section on how to do it. I built a SF using a 04 frame and had no issues for the pipe. It was a very straight forward build. Keep us posted on your progress!

[splatter]

i think you are right. i wil bee looking on how much clerance i need to make room for the pipe to day.

yes i read about the head angle problem on theese models, but dont know how to measure the angle
i dont want to make it worse than it is by just taking it out to an unknown angle

[splatter]

made som progress today cut the frame and closed the holes
next task is to see if there is enough room for the kickstarter it is wery close to the frame when its kicked all the way down :/

[motopunk]

made som progress today cut the frame and closed the holes
next task is to see if there is enough room for the kickstarter it is wery close to the frame when its kicked all the way down :/

greetings from germany ... ...
  i use also the 86 kx500 engine in my ´93 kx250 frame and a light modified ´85 klr 600 kickstarter ... enough space to my frame by kicking, fits better under the upper frame-rails, when in neutral transport position.. and reason nr 3 : it is made from steel and much stronger as any aluminium kickstarter, because i broke 2 of them in short time...  

here is the bike and a link to the complete build thread on my website...

http://der-motopunk.de.tl/projekt-kx500-.htm

[splatter]

thanks for the tip great built by the way looking good

[motopunk]

thanks for the tip great built by the way looking good

thanks.. i wanted, that it is looking like a stock bike 

[splatter]

anybody know whats the best intake boot to use, so the carb clears the shock ?

also an advice on exhaust would be nice

[zz3gmc]

91-94 KDX250 intake is what I used on my 02 500 engine. Clears the shock nicely.

[splatter]

thanks just ordered one on ebay

and im almost ready to measure and cut the swingarm to fit the frame and engine cant wait to have it standing on the wheels 

[Reddy]

I like watching these builds! They bring back good and bad memories of the AF build I did with my dad.  Although I've never been brave enough to ride a 500.

Its a shame Its a 07 frame as I have an 04 swinging arm that's already been modified for a 86 engine.

[motopunk]

I like watching these builds! They bring back good and bad memories of the AF build I did with my dad.  Although I've never been brave enough to ride a 500.

Its a shame Its a 07 frame as I have an 04 swinging arm that's already been modified for a 86 engine.

i love to ride my 86 kx500 engine in the 93-kx250 frame... perfect handling for me... 
but i have to say, that not everybody is able to ride a 500 ... sometimes is a 250 the easier ride...