KX Riders
Maintenance & Technical => KX500 Steel Frame Conversion (SFC) => Topic started by: ddashb on December 12, 2014, 03:54:32 AM
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Well I'm new to this whole forum thing so this will be crappy but I have a complete 2005 RMz250 that I'm swapping a newer generation k5 motor into. In a few days I'll have some pics up on where I am at and any input would be greatly appreciated!
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welcome to the site ddashb!
looking forward to seeing some pics.
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(http://i1091.photobucket.com/albums/i397/dirtbiker500/KIMG1290.jpg)
Well I figured how to post pics! Shouldn't be too long before it gets blown up by more!
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(http://i1091.photobucket.com/albums/i397/dirtbiker500/KIMG1390.jpg)
This is where I'm at now. With a few links to other builds I should have cut the bottom rails a little further back but I think when we get ready to finish cut and weld we'll be about to figure out what we need to do for some good support.
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If I remember correctly, I split my bottom rails a part and slide the K5 rails into them. I cut and sliced in the top and put the cradle up into it by a couple inches or so. Since it is sq on the 250f, i cut a wedge out and tapered in back together. If yours is short, you can put sleeves to get the right length.
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(http://i1091.photobucket.com/albums/i397/dirtbiker500/Mobile%20Uploads/20141215_095305.jpg) (http://s1091.photobucket.com/user/dirtbiker500/media/Mobile%20Uploads/20141215_095305.jpg.html)
Here's what we got so far. Did what we could to line the output shaft hole with theswingarm pivot but left off the final tabs until i get ahold of a cylinder head (help would be great).
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(http://i1091.photobucket.com/albums/i397/dirtbiker500/Mobile%20Uploads/20141215_095317.jpg) (http://s1091.photobucket.com/user/dirtbiker500/media/Mobile%20Uploads/20141215_095317.jpg.html)
Laid down a ton of extra weld to make sure we had enough to grind off to clean it up.
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(http://i1091.photobucket.com/albums/i397/dirtbiker500/Mobile%20Uploads/20141215_095323.jpg) (http://s1091.photobucket.com/user/dirtbiker500/media/Mobile%20Uploads/20141215_095323.jpg.html)
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(http://i1091.photobucket.com/albums/i397/dirtbiker500/Mobile%20Uploads/20141215_095720.jpg) (http://s1091.photobucket.com/user/dirtbiker500/media/Mobile%20Uploads/20141215_095720.jpg.html)
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Looking good. Maybe put an extra gusset on the bottom by foot pegs.
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Wow!
Nice progress...
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Looking good. Maybe put an extra gusset on the bottom by foot pegs.
You talking from rail to rail?
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As I recall, you will have to notch the right frame rail if you want to be able to remove the clutch cover, otherwise you have to pull motor. I also recall having to machine down the swing arm to accommodate the rear motor mount, so I wouldn't lay the mounts until I had the tranny in to make sure I had the right sprocket alignment
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will definitely be on the research train this weekend as I really am not looking forward to riding in Michigan 25 degree weather... :oops: And thanks for the help guys!
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As I recall, you will have to notch the right frame rail if you want to be able to remove the clutch cover, otherwise you have to pull motor.
Is this true even if you have a two piece clutch cover?
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I think there is another tube that angles into the back rail. The KX5 frames had a tendency to break there if I recall correctly.
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As I recall, you will have to notch the right frame rail if you want to be able to remove the clutch cover, otherwise you have to pull motor.
Is this true even if you have a two piece clutch cover?
If you have a two piece you will have no problem changing the clutch, you will still have a problem if you need to get in for any other reason. there is one ear on the cover that will not clear without the notch.
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made a ilttle progress drilling the case for the bigger rmz swingarm axle and have the bike back together to do more lining up but am really on the hunt for a good clutch-side engine cover to almost complete my engine parts list.... :wink: any leads would be appreciated.
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well I haven't made much progress with moving to alaska but I did bring the project. Where I'm at now is I have an old CR500af pipe that I am going to weld the kx5 inlet portion of a kx5 pipe onto but... no one has any kx5 stuff in alaska.
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just find someone with a lathe and have them make you one ,not much to it.
I sold my first 86 kx 500 in dutch harbor, last time I saw it it had made its way to Ancorage but that was in 89 or 90 so probably gone to scap by now.
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well it's been a long frickin' time but I have had the bike "done" for some time now. About time I post up some info about it... especially if i can remember how to post pics lol.
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(http://i1105.photobucket.com/albums/h356/Daren_Beard/20160415_184600.png) (http://s1105.photobucket.com/user/Daren_Beard/media/20160415_184600.png.html)
So here is finally a pic from me taking it out to the local motocross track here in Anchorage, well the only motocross track. Just happened to park next to a guy with the exact same bike that mine was born from lol. Was lucky and the bike starts easy and runs great on the stock jetting. Just remembering how to post so I'll have more pics and info on actually how its put together up soon.
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(http://i1091.photobucket.com/albums/i397/dirtbiker500/Mobile%20Uploads/20160331_003243.jpg) (http://s1091.photobucket.com/user/dirtbiker500/media/Mobile%20Uploads/20160331_003243.jpg.html)
(http://i1091.photobucket.com/albums/i397/dirtbiker500/Mobile%20Uploads/20160404_161459.jpg) (http://s1091.photobucket.com/user/dirtbiker500/media/Mobile%20Uploads/20160404_161459.jpg.html)
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Looking good!
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That's a good looking scooter! I really like that black and red color combination. Can you post some more pics from the build?
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That's a good looking scooter! I really like that black and red color combination. Can you post some more pics from the build?
well I didn't take a whole lot of pics as I was getting it together over this last winter because I kind of forgot about the forum. But needing a discontinued 4th output gear I came crawling back.
I'll def get some more up and the current progress
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did you have those graphics/seat cover custom made, or were they pre-available?
it's got a sharp look.
(http://i1091.photobucket.com/albums/i397/dirtbiker500/Mobile%20Uploads/20160404_161459.jpg)
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The seat cover is just an SDG cover and the graphics are a semi-custom kit from Decal works that i picked the colors and our shop put on the TMS (The Motorcycle Shop).
was going to originally go with it being a "Suzuki RM500" because I had the red triple clamps but when I started at the Kawasaki dealer I came across a late 80's ZX600r with the black and red scheme so I went with that since I knew i could come across Suzuki knik knacks that were red, ie the footpegs.
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cool...though I do like the "RM500 scheme" idea a lot.
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cool...though I do like the "RM500 scheme" idea a lot.
I really wanted to go with the RMZilla scheme but I don't think the guys at the shop would've bought me a graphics set repping Suz.
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Only have had bad luck with this bike. Got to take out for some train riding and a little dune play and the thing ran great besides the rock hard suspension. Flywheel nut loosened up so the flywheel came off and ended up shearing the woodruff key. When this happened I was kicking the thing over a bunch because of a fowled plug I thought might have been from a leaky inlet needle it backfired from the erratic timing and shattered the kickstart shaft and clutch cover. So as I get to swapping some parts I find the kickstart shaft boss I guess you call it in the right case is egged out causing the shaft to stick and not retract. New cases anyone?
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If that is all that's bad, take the case to a machine shop and have a bushing installed to match the kickstarter shaft. Cheaper and easier to do than find a set of cases now days.
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If that is all that's bad, take the case to a machine shop and have a bushing installed to match the kickstarter shaft. Cheaper and easier to do than find a set of cases now days.
Well about the cases... early in the build when I first got the cases a few years ago I got '88 cases and didn't know what was going on later on in the build. You're right about the shortage of cases so I'm looking for maybe some that need welded instead of the $600 sets currently on eBay :|