KX Riders
Maintenance & Technical => KX500 Steel Frame Conversion (SFC) => Topic started by: splatter on March 22, 2014, 05:33:21 AM
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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.
(http://"C:\Users\dennis\Desktop\Ny mappe (4)\kx250 cut1.png")
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Welcome to the forum.
Can't wait to see your progress.
Post some pics so we can see how the Danish do it :lol:
Sounds like you have the right approach.
Once you drop the engine in it becomes more clear what needs to be done.
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trying to post some pictures but im havin a bit of a problem making it work hmm :)
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(http://"C:\Users\dennis\Desktop\Ny mappe (4)\kx250 cut1.png")
(http://i74.photobucket.com/albums/i257/dennissplatter/kx250cut1_zpsec603b86.png)
cut this section away and weld in a "half pipe"
(http://i74.photobucket.com/albums/i257/dennissplatter/kx250cut2_zpsb10b9861.png)
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 picīs ;)
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?
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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!
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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 ;)
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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 :/
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_171158_zpsb63425e1.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_171207-Kopi_zps954133fd.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_170955_zps6806cc55.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_120244_zps00e602f0.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_171109_zps4f2bf48d.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_171207-Kopi_zps954133fd.jpg)
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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 :/
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_171158_zpsb63425e1.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_171207-Kopi_zps954133fd.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_170955_zps6806cc55.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_120244_zps00e602f0.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_171109_zps4f2bf48d.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140323_171207-Kopi_zps954133fd.jpg)
greetings from germany ... :-) ...
i use also the 86 kx500 engine in my ī93 kx250 frame and a light modified ī85 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
(http://img.webme.com/pic/d/der-motopunk/foto0401.jpg)
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thanks for the tip :) great built by the way looking good :)
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thanks for the tip :) great built by the way looking good :)
thanks.. i wanted, that it is looking like a stock bike :wink:
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anybody know whats the best intake boot to use, so the carb clears the shock ?
also an advice on exhaust would be nice :)
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91-94 KDX250 intake is what I used on my 02 500 engine. Clears the shock nicely.
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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 :-D
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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.
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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...
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After decades of racing enduros on mostly 250s a few 200s and a 125 I find that my 500 hybrid is the best bike Ive ever had! It handles almost as well as when it was a 250. Eats up whoop sections better than when it was a 250 and handles bar banging tight woods extremely well! My engine is pretty much stock with the exception of a heavy flywheel weight. Its geared 14/51 which allows me to pull taller gears and smooths out the power delivery quite nicely. Im usually less tired after racing the 500 than when on the 250, its allowed me to relax more and concentrate on the trail.
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After decades of racing enduros on mostly 250s a few 200s and a 125 I find that my 500 hybrid is the best bike Ive ever had! It handles almost as well as when it was a 250. Eats up whoop sections better than when it was a 250 and handles bar banging tight woods extremely well! My engine is pretty much stock with the exception of a heavy flywheel weight. Its geared 14/51 which allows me to pull taller gears and smooths out the power delivery quite nicely. Im usually less tired after racing the 500 than when on the 250, its allowed me to relax more and concentrate on the trail.
So nice to hear,, this is why I have used mine for a trail bike.
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finaly got some time to make a little progress in the garage :)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140410_171241_zpsfa145a36.jpg)
cut the swingarm to the width of the engine and got it mountet
(http://i74.photobucket.com/albums/i257/dennissplatter/20140410_161039_zps84cfb4de.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140410_160205_zps38b79b9e.jpg)
put in a 0,7mm feeler gauge in between on the picture here
(http://i74.photobucket.com/albums/i257/dennissplatter/20140410_161101_zps6d6a822d.jpg)
but is that enough distance? as you can see there is a little more room tha 0,7mm mayby around 1mm or so, but will it be enough?
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Got the intake mountet too but not really happy about the angle :/ will the angle give me a problem ? thinking of float level or over floating maybe?
(http://i74.photobucket.com/albums/i257/dennissplatter/20140331_194056_zps5e806969.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140331_194601_zps4962edda.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140331_195020_zps460e448b.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140331_194941_zpsbee77ec3.jpg)
Another expert question :-D : is there different dimensions from old to newer engines exhaustport outlet ? thalking about the outside diameter off the pipe header.
bought an old pipe that i cut up and i think its going to fit nicely on the bike (it has a SPES sticker om the silencer)
the diameter on it is smaller than the stock 86 exhaust?
(http://i74.photobucket.com/albums/i257/dennissplatter/exhdiam_zps1ed4f0c7.jpg)
its pretty rusty now but not rotten ;)
(http://i74.photobucket.com/albums/i257/dennissplatter/100998777_906_1024_0_0_0_0_2_zps41907d6e.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140330_191347_zpsbebc8d32.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/20140330_191249_zpsfbf19344.jpg)
(http://i74.photobucket.com/albums/i257/dennissplatter/100863166_906_1024_0_0_0_0_2_zps74f25d92.jpg)
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nice progress... :-) you have only to clear, that the swing arm can move free up and down without contact to the engine case... what i can see in your pics is ok and would work correctly...
but you need a bigger washer to hold your kickstarter on the shaft... :wink:
what exhaust is this? looks like 250.. exhaust ports from 86-2004 kx500 are all the same 55mm outer and 49,5mm inner diameter
clearing your carb holder problem is this way: make a spline like i did on my bike, that the carb lines up perfect to carb boot und it would give perfect clearance also to the gas tank... my spline is 10mm to 2mm ,
(http://img.webme.com/pic/d/der-motopunk/foto0318.jpg)
http://img.webme.com/pic/d/der-motopunk/foto0318.jpg
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okay yes it clears the case okay only touching the gasket sticking out from the cluchcover :)7
haha im going to use klr 600 kickstarter like you sugested erlier ;)
the guy told me it was from a 500 but i wil be measuring it later to compare
somthing tels me you are propperly right :/
that carb solution mite work for me too :)
thanks
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i had a long time to figure it out with the spline. i use the oem kx500 carb holder (87-2004) works great for the 93 frame ...