KX Riders
Maintenance & Technical => KX500 Steel Frame Conversion (SFC) => Topic started by: gwcrim on November 20, 2008, 12:45:28 AM
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Just had a 2002 KX250/500 dropped off at the house this AM. Not an aluminum frame, but a hybrid, none the less. Bought it from a guy here that goes by 'racemx'. It's in need of a bit of TLC but the price sure was right.
I'll be calling Service Honda for a pipe and looking for a powder coater to do the frame. I have lots of goodies on my '89 500 engine that will be transferred as well.
May god have mercy on my soul!
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0422.jpg)
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0421.jpg)
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:) cool!
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good luck with it. that bike looks like alot of fun. it doesn't look like it needs too much tlc to get it whipped into shape. MADDOGGY
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If you built it from scratch yourself you would be an honorary member, for now your just a prospect. :lol: :lol: :lol:
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Didn't you used to have a Rocket Science Racing perimeter framed KX500 a while ago gwcrim?
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Not me. I'm not a rocket scientist. I just play one on TV. :roll:
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Just ordered a shiny new Service Honda pipe for my monster. Had a nice talk with Stewart too. Gotta get moving on this thing. Found a powder coater that can do Kawi green for the frame but he's got a 4-6 week back log and I don't even have it ready to go.
I'll have the tabs for the pipe welded ASAP and then strip it down. Spring will be here before ya know.
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Got the pipe today. Nice pipe it is. Initial fitting is pretty good. I have a copper 180* fitting to deal with the coolant intake line. Not the most beautiful thing in the world, but certainly sufficient for the time.
The biggest headache looks like it will be the stinger. At first glance it appears that the shock reservoir is about 1/2-1" too low. Would be great to just move the upper shock mount up by 1". That would lower the bike and I'd like that too. But that's probably more of a job than removing the stinger and rewelding it at a slightly lower angle.
I'll post pics later. I'm not going to rush this job and screw things up.
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Other minor issues are that the oil filler isn't going to fit, the rear brake reservoir hits, and the bend on the silencer isn't correct.
I know..... the pipe wasn't designed for this bike. I'm not complaining at all. It's far closer than anything else. Where there's a will, there's a way.
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Hey guys, just joined the forum today! I heard good things about this site on thumpertalk, and I needed some info about a K5 project, so here I am.
I was curious if you wouldn't mind letting me know how much AJ charged for the pipe? I have a 2003 KX250 that is begging for my 86 K5 engine, and as far as I can tell, the pipe is going to be the hardest thing to get right.
Thanks,
Josh
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Didn't you used to have a Rocket Science Racing perimeter framed KX500 a while ago gwcrim?
I had a Rocket Science frame, never really liked it, the bike sat too tall, it was probably another 3" taller than a stocker and as for handling it was just a 500 with different plastic. The true hybrids handle much bettter and even sit better and the rocket science kit wa about 3k, so no real bargin there
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Hey guys, just joined the forum today! I heard good things about this site on thumpertalk, and I needed some info about a K5 project, so here I am.
I was curious if you wouldn't mind letting me know how much AJ charged for the pipe? I have a 2003 KX250 that is begging for my 86 K5 engine, and as far as I can tell, the pipe is going to be the hardest thing to get right.
Thanks,
Josh
The pipe was a about $400 and that was with the quieter, more expensive Q silencer.
We're stretching things by using that pipe on a different chassis but the right engine. An 86 engine may be quite different. Could be more trouble. Lots of cutting and welding.
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I was up until who knows when pondering the pipe. I took the shock off and the pipe actually fits pretty well w/out it. Now to get rid of that pesky reservoir. I'll see what I can find in a shock w/a remote. I don't want to cut up a perfectly good pipe and the rear shock seems to be leaking a bit of oil.
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I got the Service Kawasaki pipe stuffed in and it will fit without denting or cutting it. Unfortunately, the reservoir on the shock hits the pipe.
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0439.jpg)
This is the shock on the bike. I've never seen one with the schrader valve that hung down below the reservoir body. This takes up 5/8" where there's not any clearance anyway. Even with a recessed schrader valve there will be interference. I believe I can probably notch the body of the reservoir. Anyone know anything about this weird schrader I have?
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0434.jpg)
To mount the silencer, I'll weld a nut under the subframe for the forward mount and fab a little hangar for the rear. The fender will need a tiny amount of trimming.
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0440.jpg)
Other than mounting points for the tabs on the pipe to the main frame, that's all it'll take to fit it. (I hope.) Fabbing a coolant line to run from the pump to the jug may be challenging. I have a few ideas but a Service Kawasaki hose set sure would work too.
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Bent it were stinger (bleedingpipe) begins downwards, and bend up mufflerpipe with a sharper angle were stock bend is.
This rerouting will make muffler to fit in higher excisting hole in subframe.
Just my 2 cents! :-D
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Great idea. How do I bend that pipe without kinking it?
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that might be tricky. You might look into filling the pipe full of some sort of material like sand, i recall reading somewhere about filling tube with sand before bending for some purpose.
Worth looking into though. I think you might just be better cutting it and making it right.
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My biggest issue is finding someone who can weld aluminum. No matter what I do I need either a bracket welded to the subframe and/or the silencer. I don't see any HUGE benefit into cutting up a $150 silencer.
It's not like I can buy stainless tubing bends at Walmart and use JB Weld to stick them together. :mrgreen:
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Great idea. How do I bend that pipe without kinking it?
And what about a tube bender like this??
Dutch
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My biggest issue is finding someone who can weld aluminum. No matter what I do I need either a bracket welded to the subframe and/or the silencer. I don't see any HUGE benefit into cutting up a $150 silencer.
It's not like I can buy stainless tubing bends at Walmart and use JB Weld to stick them together. :mrgreen:
Often your local general aviation airport has 'a guy' that welds aluminum without thinking anything of it......no muss, no fuss, no drama, so usually reasonably priced ! :wink:
Mark
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Got the bike back. Two brackets welded to the steel frame, a couple of brackets made for the silencer, one for the coil, and move the lower radiator mounts forward. $80.
Guy did a nice job though he couldn't weld aluminum like I thought. I can't post pics now cuz we're out of power from that nasty storm.
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Here are a few pics of my progress. The pipe fits incredibly well. Only the clearance between the shock reservoir and the stinger is a concern. It's less than 1/4". I'll notch the reservoir to make it better.
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0498s.jpg)
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0495s.jpg)
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0499.jpg)
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0500s.jpg)
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0497s.jpg)
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Mine was close but I was able to fiddle with the mounts a little and got it in the 1/4" range with no prob.Is the one mount welded to the pipe yet I'm not running that mount but have considered putting one. I was going to run it off of the back of the frame on the other side and kinda hide it behinde the frame spare. I wouldn't grind on the shock res you gotta be able to another find 1/8" somehow.
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I got the Service Kawasaki pipe stuffed in and it will fit without denting or cutting it. Unfortunately, the reservoir on the shock hits the pipe.
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0439.jpg)
This is the shock on the bike. I've never seen one with the schrader valve that hung down below the reservoir body. This takes up 5/8" where there's not any clearance anyway. Even with a recessed schrader valve there will be interference. I believe I can probably notch the body of the reservoir. Anyone know anything about this weird schrader I have?
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0434.jpg)
To mount the silencer, I'll weld a nut under the subframe for the forward mount and fab a little hangar for the rear. The fender will need a tiny amount of trimming.
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/HPIM0440.jpg)
Other than mounting points for the tabs on the pipe to the main frame, that's all it'll take to fit it. (I hope.) Fabbing a coolant line to run from the pump to the jug may be challenging. I have a few ideas but a Service Kawasaki hose set sure would work too.
I had to trim my fender on my 02 KX250 for the Q silencer, just doesn't quite fit exactly. The d**n thing is so long. haha
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Been over two years since I bought this bike and still it's not done. Gave up on the cases I paid for last April that haven't showed up and bought another set from Yunggunnaz. They used to hang around here a bit. It's out of a dirt drag bike they ran. Found a guy near by that will powder coat the frame for about a buck and a quarter. I'm going with....... green. How original.
Once I get the frame and bottom end here its nothing but reassembly from bare cases and frame. Hope to have it done by spring.
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crim,
did you change shocks? one picture has the schrader valve way out the other in inset. Also that head looks like the one I had for my Rocket science framed bike.
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I did get the right shock. If anyone can identify the old one I'd appreciate it. I'd like to sell it.
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So..... over year later and I finally took the parts to a machine shop to get the swingarm and bushings cut to fit the bike. May actually make some progress this year. Nest up is powder coating the frame and getting the bottom end done.
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Keep plugging away Crim! Will be sweet when you are done with it.
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What cyl head is that?
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The head is one of Stewarts billet jobs. I sold it though.
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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??
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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.
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Can't wait to see what you come up with..
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wow...just read the whole thread, sounds interesting...love to see some updated pics.
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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.
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Here's what I have to start with. New bearings all the way around.
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/IMG_20140128_182951_901_zpsb418af7d.jpg) (http://s185.photobucket.com/user/gwcrim/media/kx250-500/IMG_20140128_182951_901_zpsb418af7d.jpg.html)
Along the way, I picked up a Rev Lock clutch. Fasteners are missing. Anyone familiar with these?
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/IMG_20140128_185316_779_zpsee0892a6.jpg) (http://s185.photobucket.com/user/gwcrim/media/kx250-500/IMG_20140128_185316_779_zpsee0892a6.jpg.html)
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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"! :lol:
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Pics, eh. It's 100% disassembled.
ahhh...yeah I see your point...that would be A LOT of pics. :lol:
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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?
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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.
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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.
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I have an entire spare 2000 engine minus the crank and head. Let me know what you need.
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I sent you an email but.... I need everything inside of the cases.
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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.
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Just a peek at the combo coming together. Progress is slow but sure.
(https://scontent-a-iad.xx.fbcdn.net/hphotos-ash3/t1.0-9/1800438_10203376591360659_833736481_n.jpg)
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cool...frame's looking nice.
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Nice looking frame,Did you go powder or paint?
Noticed you welded on the front for the exhaust mount as well. Looks almost identical to mine.
Nothing like a good basket case coming build coming together :-)
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Frame is powder coated. It's the only way to go. I'm thinking black plastic would look great on it. But after a while it might not.
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Yeah, just got my frame back from powder as well, It was the first time I have gone that route.
It makes for an awesome finished product.
Just waiting on my crank to be sent back from balancing, then it's all going together after collecting parts for 2 years.
keep posting pics :-)
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The big delay lately has been the bearings for the clutch release lever. Or should I say the lack thereof. I ordered two and somehow destroyed one. Ordered a replacement off Ebay and it's a low quality POS. I may put the engine in the frame w/out the upper bearing. I believe I can get it done that way.
The old 250 donor is completely stripped. Bizarre how you have to remove the engine (or at least the clutch cover) to get the footpeg off. Post mortem so far has revealed pieces of melted aluminum in the exhaust pipe. The engine is locked. I'll keep any parts that can be used as spares so that means pretty much just the engine and exhaust will be sold.
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It's always two steps forward, one step back. Got the rear suspension pretty much done. Found out the triple clamps on the bike (99-01) are the wrong size for our (2002) Pro Action forks. Had to order new neck bearings as I'm sure as hell not going to be able to remove the lower one I just put on the smaller clamp. FEH!
(https://scontent-a-iad.xx.fbcdn.net/hphotos-prn2/t1.0-9/10154941_10203712142469227_7301749660096669070_n.jpg)
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So an update on my imaginary dirt bike. Finally found a guy to weld the tank. I thought he would measure, cut and weld but he only had welding in mind. Tonight I cut up a perfectly good, $300 tank. I'll show pics later but it looks really good and it should fit like a charm. Need to get some polypropylene sheet to fill it and we're making progress again.
I sent an email to JFab last Feb about a head stay. He seems to have dropped off the planet. Anyone hear from him?
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Tis the season: It's beginning to look a lot like dirt bike!
(http://i185.photobucket.com/albums/x96/gwcrim/kx250-500/20141116_140048_zpse0ecf159.jpg) (http://s185.photobucket.com/user/gwcrim/media/kx250-500/20141116_140048_zpse0ecf159.jpg.html)