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Author Topic: 2017 KX250F - 2004 KX250  (Read 3943 times)
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umberto
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« Reply #15 on: February 11, 2018, 08:15:44 PM »

After a long break, I am finally ready to tackle this project again.  I have a buddy who is a machinist that is going to help me with getting the frame sections swapped out, and the motor mounts and head stay fabricated.  He has a way of simplifying things that makes things go swiftly and easily.  In preparation for taking the stuff back to my home town, I worked on getting the swingarm fitted to the engine.  The swingarm did need some shaping at the front, but luckily the engine is narrower than the swingarm opening.  This allows me to fine tune the chain alignment and fabricate the spacers as needed.  There's not much to show, but here is the swingarm after I sanded it to fit.



I also had to purchase 2017 radiators to use, as the 2004 models just wouldn't fit the frame at all.  I was able to score a set of stock radiator hoses with the y fittings to try to modify the hose routing to fit the KXF radiators.  On a positive note, I was amazed at how well the CR cradle lines up with the KXF frame.  It will really simplify things.

I think I have all the parts accumulated, now it's time to just do it.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
2017 KX250F/2004 KX250 - Project Back Burner
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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« Reply #16 on: February 12, 2018, 12:17:58 PM »

I had a quick radiator question to make sure I am routing the hoses correctly.  It appears the two stroke radiators go in the bottom of the right radiator, cross over at the bottom to left radiator, and flow up to the top where the right radiator crosses over to the left radiator and the coolant flows out the hose to the cylinder head and down to the water pump again.  It appears the four stroke is similar, it just splits the hose instead of using radiator cross overs.  Is that correct, or does it flow the other direction?
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
2017 KX250F/2004 KX250 - Project Back Burner
04 KX 250 - Lunchbox's Bike
05 KX 125/144
SS109
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« Reply #17 on: February 12, 2018, 03:47:32 PM »

The waterpump pulls from the right radiator and pushes the coolant up through the engine. It exits the cylinder head and goes to the left radiator.

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'90 KDX 200 (rebuild - DONE!) - '94 KDX 250 (soon to be a KDX250af)
umberto
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« Reply #18 on: February 12, 2018, 05:01:44 PM »

Okay, I had it backwards then.  Using the KXF radiators, I will plum the bottom tanks of both radiators to the water pump, and the top of both radiators will go from the top of the cylinder head to the top of both radiators.  All I need to do now is find some y and t connectors to use to replace the stock ones that actually attach to the head and water pump.  Anyone have any suggestions on where to find some?  Here is the stock configuration:

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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
2017 KX250F/2004 KX250 - Project Back Burner
04 KX 250 - Lunchbox's Bike
05 KX 125/144
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« Reply #19 on: February 12, 2018, 05:21:01 PM »

Cool... but if there are no pics, you know the rules... It never happened...  cheesy
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
umberto
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« Reply #20 on: February 12, 2018, 06:16:43 PM »

I'm out of practice on taking pictures.  I promise more are on the way.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
2017 KX250F/2004 KX250 - Project Back Burner
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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« Reply #21 on: February 12, 2018, 09:19:59 PM »

I had to order some motor mount bolts for the CR cradle, and just happened to look at the 2001 CR radiator fiche. Low and behold, there was the perfect upper fitting!  I then did a little more digging and found a fitting on a RMZ 250 that might work for the water pump. If they both work, that should wrap up my radiator issues.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
2017 KX250F/2004 KX250 - Project Back Burner
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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Goliath Returning from Battle


« Reply #22 on: February 14, 2018, 08:39:51 PM »

I got the frame and stuff down to my buddy today. Thankfully my wife isnt crazy about Valentines Day, so she let me have the day off. After digesting all the specifics, he said, I cant really get started on it for a while.  It has been a while on this project, so I wasnt too disappointed, but I was hoping for a fairly quick turnaround. Especially since hes so quick on other things. Then he said, I cant really get to it until Monday.   shocked

Now we should start picking up steam.
Logged

Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
2017 KX250F/2004 KX250 - Project Back Burner
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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Goliath Returning from Battle


« Reply #23 on: February 16, 2018, 03:15:55 PM »

I got a little work done today on a few issues that aren't related to the frame.  The first is the fuel tank.  Because it is fuel injected, there is a large hole in the tank for the fuel pump and no petcock.  I am going to fabricate an aluminum plate to cover the hole and mount a remote petcock from a 2008 KX450F.  



I decided to do it in two pieces that will be welded together after I am done.  The reason I did this was to keep the threads that mount the remote petcock from being exposed to gas.  That way I don't have to weld over the threads to seal them, possibly damaging them.  Anyway, I took measurements and cut out a circle from cardboard, marking the holes for the mounting bolts.  I then cut out a piece to mount the petcock.



Here is the finished petcock mount.  I chamfered the edge to the gas will be able to flow a little better.  The hole in the larger piece will be sized to match.  




I also got my radiators and hoses in today, and was able to look at hose routing.  One issue you run into with the newer radiators is that the hoses are 16 mm instead of 18 mm like the older bikes.  Also, the fittings bolt directly in to the head and water pump, unlike the old ones that attach with hose clamps.  



Thankfully some older model bikes came to the rescue.  The 2001 CR 250 had a top fitting that is 18 mm at the bottom and 16 mm at the ends.  It is shaped exactly like the stock KXF as well.  Score!



Here it is in the hoses:



The bottom one is a little bit trickier.  It has a pretty funky bend to it.  I found this one from a 2012 RM250Z.  I think it will work if I flip the left side radiator hose and tweak the bottom hose a bit.  I'll have to wait until I get the frame back to be sure.



That's all for now.  Hopefully I will have the frame back in the next couple of weeks and will be able to post more updates.

« Last Edit: February 16, 2018, 10:01:40 PM by umberto » Logged

Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
2017 KX250F/2004 KX250 - Project Back Burner
04 KX 250 - Lunchbox's Bike
05 KX 125/144
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