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Author Topic: 2017 KX250F - 2004 KX250  (Read 20650 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
17 KX250F/04 KX250
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
17 KX250F/04 KX250
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
17 KX250F/04 KX250
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
17 KX250F/04 KX250
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
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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« Reply #22 on: February 14, 2018, 08:39:51 PM »

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

Now we should start picking up steam.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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« 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
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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« Reply #24 on: February 24, 2018, 01:00:24 PM »

I have a couple more areas that I will need to tackle before the frame gets back.  One of these is the triple clamps.  The bike came with the stock 2017 triple clamps, but they are too large for my 2009 KX250F forks.  I could use the existing Ride Engineering clamps that I have, but they are 25 mm offset versus the stock 2017 offset of 22.5 mm.  I really want to use the 09 forks, because they were redone by Stillwell Performance and work really well.  I checked with Pro Circuit Racing to see what clamps they had, and I noticed they only offered one set of clamps for the 2017 in 22 mm offset.  Thankfully, Ride Engineering offers a set for the 2009s that is 22 mm as well.  I pressed the 2017 stem into the clamps and the problem was solved.  I bought a set in silver finish, as I might be going for a Pro Circuit theme with the Graphics and plastic.  I keep going back and forth between that and stock look.  Oh well, got to have the bike together before I worry too much about how it looks.   grin



My forks:



Next up is rebuilding the back brake master cylinder and getting the 2017 brake line installed.  I'll keep you posted.
« Last Edit: February 24, 2018, 04:00:36 PM by umberto » Logged

Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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« Reply #25 on: April 17, 2018, 06:38:05 PM »

Hallelujah, the frame is done!  My buddy got it finished last weekend, and I drove back to my home town to pick it up today. Iím very pleased with the results!  Iíll try to get some pictures this weekend, before and after I mock it up.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
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« Reply #26 on: April 17, 2018, 09:41:23 PM »

Looking forward to it...
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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 #27 on: April 18, 2018, 06:35:39 PM »

The first picture is the frame as I got it.  The welds are really nice, and the motor is straight.  I'm going to do some reinforcement on the head stay; I just don't think it is nearly stout enough.  The frame does not have a clean place to attach anything under the seat, so I am trying to engineer something using the stock head stay location.  Thankfully it is uphill from the head and has two attachment points to prevent rotations.  I'll post pictures of what I come up with.

I was able to get the swingarm and linkage on, subframe and airbox, tank, and the footpegs on.  I will have to reconfigure the radiators a bit, as the KXF radiators are very long and won't work with the higher Y piece.  I'm going to try the KX radiators and if those don't work, I may have the KXF ones cut down.  The other issue I ran in to was the kickstarter.  If you set it in its normal position, it hits the frame.  If you put it forward one notch, it hits the clutch cover.  I'm going to look at some KXF ones to see if I can engineer something.  If not, maybe I can talk my buddy in to making me a billet one.  Other than those two things, the rest of the stuff is going on pretty well, and it should be a really straightforward build.  The pipe needed a small dent on the back side, but it should fit without much modification of the mounts.  The airbox may need a spacer, but it looks pretty straightforward as well. 

The second picture is where I got to today.  I'm having my suspension redone at N2Dirt and it worn't be in for a few weeks, so the bike won't be moving for a while.  My next steps are to get the rear brake rebuilt and set up, the motor spacers fabricated and installed, and the airbox mocked up.  Then it's on to the tank cover plate, the radiators, and finally the kickstarter.



* IMG_0849[1].JPG (3127.52 KB, 4032x3024 - viewed 85 times.)

* IMG_0850[1].JPG (3588.25 KB, 4032x3024 - viewed 72 times.)
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
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« Reply #28 on: April 18, 2018, 08:30:57 PM »

Looking good! You're almost there!
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North Las Vegas

"05" RMZ450, "08" KX500AF "11" KTM 450SX-F "12" KTM 250SX "15" KTM450SX-F
umberto
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« Reply #29 on: April 18, 2018, 08:57:38 PM »

Looking good! You're almost there!
Thank you sir.  Iím excited to finally be moving forward.
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Perhaps I have a dirt bike addiction?

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