Can I join the club?

[gwcrim]

The head is one of Stewarts billet jobs.  I sold it though.

[jrowley85]

hey gwcrim, im lookin into doing one of these builds when i get back and since i dont own a machine shop i was wondering how much it cost you to get the swingarm, bushing, and motor drilled out??

[gwcrim]

No one can be wondering what happened to this build more than ME.  5 years later, I'm back on it.  I could write a book about the BS that has happened to the engine.  Many of the chassis parts have been scavenged to fix another 250 that my son has worn out.  Been through a KLX450 and now on a KTM 300.  Regardless...

Bottom end is done.  Frame is powder coated.  I'm going into full assembly mode before I die of old age.  I'll try to take pics and document as much as I can. 

Two biggest hurdles left:  fuel tank and head stay.  There is a plastic shop near my house and I hope to convince them to cut and weld the tank.  Head stay ought to be easier.

[sandblaster]

Can't wait to see what you come up with..

[Foxx4Beaver]

wow...just read the whole thread, sounds interesting...love to see some updated pics.

[gwcrim]

Pics, eh.  It's 100% disassembled.  A certified basket case.  Bike in a box.  My youngest son calls it Dads imaginary dirt bike.  He was 5 when I got it.  Once I get started, I'll post some pics.

The current plan is to canabalize the 250 my older son now rides.  The suspension on the 250 is set up for him and I'm really digging the KTM so we're going to make 1 bike out of two.

So......... I suppose I ought to be downstairs working on it instead of surfing.

[gwcrim]

Here's what I have to start with.  New bearings all the way around.




Along the way, I picked up a Rev Lock clutch.  Fasteners are missing.  Anyone familiar with these?

[Brute]

That makes me feel better that I am not the only one that took a 'time out' from the KX5 project to work on other bikes. Thanks! Looking to donate my GL500I and get a tax break as well as getting another project out of here. I was going to make a cafe bike out of it since I have not been able to sell it as is. Been riding it for about three years since I put it together. Better to donate it and be done with it. best of luck on your KX5. Will look foreword to some progress on the 'imaginary dirt bike"! 

[Foxx4Beaver]

Pics, eh.  It's 100% disassembled.

ahhh...yeah I see your point...that would be A LOT of pics.

[gwcrim]

Started digging though boxes tonight.  Hard to think there's a dirt bike in all of them.  Can't find all the KIPS drive parts and what's there is pretty worn.  Ebay?  New?

[Brute]

I have done a few projects that started as boxes of parts like that. When I find parts missing I wonder if I should have looked closer or if it would have made any difference to me.
Some of the more advanced in KX5 parts procurement will probably chime in. I do not know. Hope I do not have to find out any time soon!
Be looking foreword to reports on how it is going.

[gwcrim]

I priced the parts new and OUCH is all I can say.  I'll look around a bit more.  If anyone has any spare parts, let me know please.

[Pmcg]

I have an entire spare 2000 engine minus the crank and head. Let me know what you need.

[gwcrim]

I sent you an email but.... I need everything inside of the cases.

[gwcrim]

As of last weekend our KX250 engine is toast.  The boy seized it cuz he thought there was a statey on his ass.  Not sure why the hell he decided to stay on the road when there were woods all around  but i digress.......

The 250 donor bike is now very available for donating.  The suspension was set up for my son so it's going on the build.  Will take a close look at the tank.  I think it's a Clarke.  Wheels on it are pretty beat.  Might go with a fresh set of Warp 9s.  Hate to spend all this money and not the extra nickel for new plastic too.

Right now I"m waiting on the studs for the case so I can put the top end on then start putting parts on.  YIPPEE  I'm sure there are plenty of headaches ahead but she's on the assembly bench finally.