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Author Topic: Making 1995 kx250 work in 1998 kx250 frame  (Read 1942 times)
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Egossett87
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« on: July 01, 2017, 06:35:44 AM »

Hello, this is my first post so take it easy on me. I apologize in advance if this has been covered before. Ok; so I started building a kx 250 with just a frame. The frame is a 1998 kx250. And I've been ordering all my parts for a 98. Most everything has been smooth until I ordered my swingarm. The motor I have is from a 1995 kx 250. So when I went to put my swingarm on the motor casing is way to thick to fit the 98 swingarm on. I figured I would have to use a 1995 swingarm to attach properly but wanted to get some more input before I buy another one and it not work as well. Any input would be great! Thanks in advance!

Eddie
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KXDINO
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« Reply #1 on: July 01, 2017, 01:15:52 PM »

are you talking about the width of the back of the engine, if so how much difference are you talking about? if it to much to machine off , i would use a 95 part.
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Egossett87
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« Reply #2 on: July 01, 2017, 02:54:55 PM »

About a 1/4 to 1/2 inch off each side. But I really don't want to cut into the motor cases. So was wondering if the 95 swingarm would work right and also if I went with the 95 swingarm if I would have to use other 95 parts such as the linkage, shock and rear wheel. Or if I can still use all the 98 parts with the 95 swingarm
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Egossett87
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« Reply #3 on: July 06, 2017, 12:44:00 PM »

Anyone? So without cutting into anything Will I need to run a 1995 swingarm to fit the 1995 motor? That's what it looks like to me but would like some other opinions. And if I do run the 1995 swingarm; is the rim a different width? Can the 98 rear shock and linkage work on a 95 swingarm or will that stuff have to be 95 too? I know the brake caliper bracket is different. Wanting to order the correct parts ASAP and give it some life 🤘😝🤘
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umberto
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« Reply #4 on: July 06, 2017, 01:03:21 PM »

I'm guessing that you don't already have the 95 swingarm, or you wouldn't be asking if it will work.  Have you considered cutting your 98 swingarm down?  I had to cut mine down to fit the 500 in my 03 250 frame.  I cut mine with bandsaw (although I have seen people use woodworking saws with a carbide blade) a little large and then use a belt sander to fine tune the fit.  I just put the motor in the frame with the swingarm bolt and motor mounts installed, measured what I needed on each side and then repeatedly test fit the swingarm as I sanded until it fit.  It took me about an hour total.  You will need to put new bearings in the swingarm, and to cut down the races.  For the races, I put tape on the until they would sit flat in the cut off saw and then cut them.  If you don't put the tape, they won't sit flat or cut straight.

If you still want to try the 95 swingarm, I would just buy a cheap one and give it a try.  You may be the first person to try this, and can educate the rest of us of if it works or not.  Worst case you could always re-sell it on eBay.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
04 KX 250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
Egossett87
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« Reply #5 on: July 07, 2017, 01:02:51 PM »

Ok, so I ordered a 1995 swingarm this morning. When it gets here I'm gonna see if will fit the motor casing. If it does I'm gonna take measurements on it and the 95. If they are all the same the 1998  linkage and shock should work. And like I said. I just started with a frame 5 months ago and have been picking up parts from time to time. But I will keep you guys posted. Hopefully I'll get it right and help another rider down the road who's doing this as well
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Egossett87
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« Reply #6 on: August 25, 2017, 02:40:45 PM »

Ok. Ive been busy with the kids sports and vacation. Finally home and have some time to give some updates. The new swingarm I ordered from eBay didn't fit and I lost a lot of momentum for the project. After some time away from it I went back and went over things. Ran the numbers on the motor casing and the motor is a 1993. The guy I purchased the motor from said it was a 95 and I took his word for it. So that was my fault. But anyways, I have the right parts on the way and moving forward with it. Not sure how to post pics on here yet.
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Egossett87
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« Reply #7 on: August 29, 2017, 05:45:45 AM »

Ok. I made a photobucket account and loaded a few pics in there. Here she is so far

<iframe width="480" height="360" src="http://s50.photobucket.com/user/Egossett87/embed/story"></iframe>

« Last Edit: September 01, 2017, 09:07:35 PM by sandblaster » Logged
Egossett87
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« Reply #8 on: September 01, 2017, 08:29:29 AM »

Ok, so I have to admit defeat.... after a lot of research and talking to other people and taking measurements from other bikes and machine shops it is impractical to try to make that motor work. So the final solution.... I ordered 1998 cases. Less headache and won't have to get anything milled or custom made.... I guess everything will be smooth sailing now.
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sandblaster
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« Reply #9 on: September 01, 2017, 09:14:45 PM »

98 cases will require 96-01 shift forks, 96-00 shift fork shafts, 97-02 shift drum.
I can't think of anything else you will need but don't be surprised if you do.
You will use one less case bolt as well  shocked
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
Egossett87
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« Reply #10 on: September 08, 2017, 01:51:46 PM »

Yes, it will require the newer shift forks. I got a new new parts  afro I ordered new cases, 1998 transmission ( got new gear shift mechanism with it), 98' rear brake bracket and that's all I can think of for now. But I was really happy about the 98 transmission with their notorious first gear!!! Gonna go ahead and get a 98 power valve, magneto, wiring harness, carb, cdi and ignition coil. Will get started on building the bottom end Monday. Taking my oldest son and nephew riding this weekend🤘🤘. The cylinder I got needs bored bad, but I may get a new sleeve put in so I can start fresh. So after I get the sleeve taken care of I will start building the cylinder. It came stripped of all the power valve stuff. So if any of you guys need 93 motor parts I will have them.
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shrubitup
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« Reply #11 on: September 09, 2017, 12:09:35 PM »

Here's somebody who had to stuff a 94 motor into a 93 frame. They had to cut down the 94 swingarm to make it work. https://thumpertalk.com/forums/topic/386159-1993-kx250-motor-in-1994-frame/
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Egossett87
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« Reply #12 on: September 09, 2017, 08:57:38 PM »

Believe me. I looked into it. But if I cut my swingarm I would have to get custom bearings made every time I need to replace them. But no worries now.
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Egossett87
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« Reply #13 on: September 11, 2017, 07:18:38 AM »

Had a good time at haspen acres in laurel Indiana yesterday! My son and nephew had a great time. So today I'm starting on the engine for the kx. Before I I start tossing in the guts I'm going to sandblast the cases and spray them with a close to factory silver as I can. Yes I know they are bare metal but I want them to look brand spanking new. I tried the eagle mag wheel cleaner on my 400ex and it still had the stained color to it so I'm painting this one. So I'm gonna paint the case haves and all the covers here in the next hour or so and let them get good and dry before I load the guts in
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umberto
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« Reply #14 on: September 11, 2017, 09:12:12 AM »

You could send your cases to Sandblaster and have him Vapour Blast them.  They will look better than new without the paint.
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Perhaps I have a dirt bike addiction?

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