Author Topic: 2003 KX 250 SF Conversion  (Read 159414 times)

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Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #330 on: March 12, 2019, 12:43:43 PM »
No suspense.  :-D. I went with silver and flat black on the frame guards.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #331 on: March 16, 2019, 05:42:31 AM »
The only small issue I have with the plastic conversion kit is that it leaves the airbox a little more open than I would like.  It may not ever be a problem, but I just don't want to take chances with as much mud and sand as we ride in.  I fabricated some plates from aluminum to fill the sides of the box so that it is better covered.  I did notch it for the openings in the side plates, so the airflow should be good.  I used a rivnut to hold them in place, and painted them in semi gloss black.  They are removable if I ever want to remove the plastic conversion.  Overall I am pleased with the results, but I ordered some ABS plastic from the devil (Amazon) so I may redo them in plastic down the road.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #332 on: March 16, 2019, 05:43:56 AM »
Here it is after I painted it.  The scratch is covered by the side panels, so I'm not going to worry about it.  That's what I keep telling myself.   :-D
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #333 on: April 02, 2019, 02:28:47 AM »
Got my frame and other parts back from the powder coater yesterday. Ready to start final assembly.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #334 on: April 02, 2019, 03:50:20 PM »
Weíre waiting on big print job at work, so it was a little slow today. I was able to sneak out and get a little work done. I got the motor in, the forks on, the wheels installed, the new IMS pegs installed, the radiators installed, and the wiring and electronics installed.  Iím pretty close to done, with just a few items to button up. One of the slow downs is the rear brake carrier.  I wanted to use a TM Designworks rear hub carrier for a 2009 and up KXF, and I thought from my experience with my AF conversion that it would bolt right up. Unfortunately the calipers are slightly different, so I have to use the KXF caliper and brake line. I bought a used one on eBay, so Iíll be waiting to finish until it arrives.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #335 on: April 05, 2019, 09:56:42 AM »
I made some more progress today. It’s mostly done, I just need to install the back brake and chain. I switched to an 09 rear brake caliper so I could use a TM Designworks rear brake guard and carrier. The 03 caliper hits on the swing arm due to a change in where the banjo bolt attaches. Here is a picture of where I stopped.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline ftc

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Re: 2003 KX 250 SF Conversion
« Reply #336 on: April 05, 2019, 11:32:54 AM »
she's a beauty, let the good times roll!  :-D

Offline sandblaster

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Re: 2003 KX 250 SF Conversion
« Reply #337 on: April 05, 2019, 01:59:39 PM »
Yep... that bike looks sweet...
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #338 on: April 05, 2019, 04:45:36 PM »
Thank you!  I'm going to have some pictures made, and then it's back to the dirt.  I've been cleaning on it for two solid weeks, so it may be hard to get it dirty at first.   :-D
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #339 on: April 07, 2019, 12:02:00 PM »
I got some more done today. I added the graphics, chain, case guard, and fixed a broken CDI mount. All I lack now is the brake caliper and line, airbox mud guard, and frame tape. The USPS may or may not have them close by. Their tracking is garbage.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #340 on: April 07, 2019, 12:09:10 PM »
I had the CDI mounted on the side of the frame because it wouldnít mount behind the number plate without a fork hitting it when I turned. The mounting bracket cracked off, so I needed to find a better way to mount it. It really cleans up the wiring to put it behind the number plate, so I bent up a steel bracket, welded it to the stock mount (that I miraculously kept), lined it with rubber matting, and zip tied it in. I think it will be way more secure and the wiring is a lot cleaner.

One other change I made was to run the wiring forward and up the clutch cable, instead of back and up the frame rail. I think it looks a lot better, and I donít have to put zip ties on the frame.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #341 on: April 10, 2019, 02:39:41 PM »
A couple more finishing touches tonight before I get some better pictures made on Friday. I added the frame tape I found on eBay, the rear mud guard, and the 2009 KX250F rear caliper. I was able to use the 2003 brake line with the KXF caliper without any trouble. Here are a couple of pictures I took.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #342 on: April 12, 2019, 12:04:33 PM »
I decided to get some pictures made of Goliath. I was able to get a different photographer, but at the same studio. This guy had a lot of great ideas for different angles and lighting. Iíve seen a few preliminary images, and they were really nice even before editing. I took a few pictures of the setup; Iíll post the final results when he sends them over.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: 2003 KX 250 SF Conversion
« Reply #343 on: April 12, 2019, 12:05:39 PM »
Iím really excited about the pictures with this background. They looked great on the viewfinder of the camera.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline reklessj

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Re: 2003 KX 250 SF Conversion
« Reply #344 on: April 12, 2019, 04:36:47 PM »
Man those pics need to get framed n put on the mantle right next to the family photo😂🤣🤣😂😂
My rides: 1994 KX500, 1988 T4, 1998, ZXI 1100 JETSKI, 2003 MOUNTAIN CAT 900
WIFES (Baby Fiver) rides: 2004 KTM 105SX,1992 LT250R, 1995 ZXI 900 JETSKI,  2011 RMK 600
SONS ride: 1995 YZ125,2002 RM 250
other rides: 2007 RMZ450 RC Ediition, 2003 RMK700