Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
K5 Rebirth
junk man:
What i did was opened up the holes and used the bushing out of an 250 link then welded them in it was a lot of grinding with a stone on the outside and a flat wheel on the inside
also make or have made a good head stay look at BDI"s build
with a 2003 or newer you could use the 500 one but the 90's and the year we used 99-02 the gas tank is in the way and then you will have to use a heat gun to reshape the bottom of the tank.
you may be thinking about using your 500 radiators don't to much trouble making them fit.
the air box will need some tweaking i removed the two rivets and let it fold up and trimmed it the carb boot some said they use a KDX 250 one i used 2000 boot and vforce 3 it came with two air inserts i used the on for jet sky i would check in to the KDX one
good luck JM
Suva:
Well, stubbornness lost- using the 250's swing arm now. seems there's a reason most everyone else did... Having a lathe an welder would have made using the 500's a lot easier.
Bored out the cases and started working on the swing arm yesterday. For widening the s/a out, used an angle grinder to get semi close then swapped to a flat file to avoid screwing it all up. Combo square helps keeping things, uh, square :wink:.
Having major difficulties with the 250's linkage though. bearings are froze on pretty good, cant even get the seals out! Soaked em in PB Blaster (basically same as WD-40, but better) all night/most of the day but still no luck. Heat didn't do any good either. Any ideas? would rather not have to order a new one...
Was looking at the 250's pipe and noticed the header(?) flange is the same dimensions as the 5's. Never really been around a KX250 before an never thought about comparing with a 250's pipe before. Might save the OEM K5 pipe from destruction...
Expecting the new DEP pipe in tomorrow.
damage on linkage from previous 2 owners riding on destroyed bearings
Just can't seem to get these darn things out!
Suva:
Hmmm, anyone wanna trade 250 linkage for 500 linkage? Or possibly other K5 parts :-D?
sandblaster:
To get the bearings out you will need a press and the correct socket sizes.
No press?
You can do it with a large C-clamp and the correct socket sizes but it is a lot harder...
junk man:
look on eBay or throw a cheep set of bearings in for now and grease the piss out of them for now
keep us posted JM
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