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Hi KXDino, I only race at a local races and there is no checking of engine numbers or chassis.
I was looking for a good 94, but gave up as I could not find one.

Any help is really appreciated.

thanks

Update:

1. Head came back from Larry. Its so d**n nice I almost didn't install it. It also makes everything else look like crap lol. Thanks Larry!

2. Good call on the Meteringblock oring. I barely touched it and it broke apart. New o-ring and 1368n needle clip on center with 168/52 installed. Couldn't find a 170 local to me.

3. Got the Top end done, motor is in bike. Need to order some new rubber mounts for the radiators.

The bike is cold and jetted very rich but you get the idea...
Does your KX500 sound like this?

https://youtu.be/kkRBUPYFgVY

Yes, the shop is dirty... So what 

how strict are these guys on having the correct engine and frame numbers, no good going to the trouble of making it a 94 and they wont let u ride it as it really a 98 by the numbers.

A little back ground on this project. Because it's made from Titanium it's very hard to find someone to weld it. Turns out Rob lives a few miles down the road and was friends with Alex Ward as kids growing up. Also, Ti is very hard to polish, drill, cut, whatever. I suppose if you have the right tools and know what you are doing would greatly help. I know nothing 😲 Anyhow, I showed Rob what I wanted done after I pulled the stock set up apart. I even ground all the internal welds as I had to put a new, larger diameter core in it. That meant that all the capture parts for the core had to be removed and redone. Because the Ti is so hard and so thin we could not bend the tubing with anything that we had so Rob cut little pie pieces of tube and welded and fit them one at a time. Needless to say it was a lot of work. If I was doing another I would use Stainless steel. But in the end, I am very pleased with the results and it sounds great. Yes, It's a little short for a KX500 silencer but with this engine I don't think that will be a issue. But we will know a lot more later this coming week. Jetting, testing, and tuning...

Hi Guys,

I just bought a 1998 KX250 which I want to race in the pre95 class, so I want to make it into a 94 as much as possible.
This is my first Kawi, so I am not sure what are the significant changes that were made between 94 and 98.

I understand the swingarm is fatter. Will a 94 swingarm fit?
Carb is a powerjet. Can I just replace with a new Airstryker?
Forks are 46mm, and not 43mm.


Hoping someone can help me out. Appreciate any info.

Cheers

I would guess he wants to relieve stresses in the frame and welds. Not really 'heat treating', more 'normalizing' but pretty much the same basic process. I would not think you would want an aluminum frame 'too' hard to allow it to flex some?

Oh yeah...
That's what it takes to fit 

Side notes:
As soon as the Ti reaches temp, it colors.
You don't have to keep it at that temp.
In fact, keeping it at temp will not change the color at all...
Only going up in temp will change the color.
Re-cored to a larger diameter, colored, modded to fit, and assembled.
Ready to mount.

Interesting looking inlet pipe!