Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
K5 Rebirth
Suva:
So much for keeping up with this...
I've had the bike running for a bit now. been hard to get around to posting pics as I don't have internet at home anymore...
Wound up using an FMF pipe from Service Honda (Thanks a ton AJ!!!) as every time I touched the DEP pipe in one place, it screwed up what I did somewhere else (very thin compared to the FMF). I also tend towards the brute force methodology, so others might have better luck with it. Still have it though, might work on it more later to use as a spare.
Had to pick up some Yamaha(?) snowmobile exhaust springs as the ones I had were way too short.
The FMF only needed minor massaging to gain a little more room, and I did wrap the rad hose with some reflective tape as added insurance. Also cut the front mount off and welded a 250 mount (mocked up better than the 500 mount) low on the chamber to match the frame mount location.
Used a new 250 clutch cable, and filed the lever a touch to give the cable a little play. Works great!
The intake boot is still super close to the rear spring, which worries me. Saw someone here mentioned a kdx 250 intake manifold helped him, so will try that.
There were a few other things I was going to mention, but they're skipping my mind at the moment...
Must say however, with this engine in a capable chassis it is a beautiful thing in the woods. And yes, even and/or especially in the tight single track we have in the mountains of N. Idaho. You HAVE to love that low end grunt! Woo hoo!
Suva:
Soooooo, after one layoff and two moves later....
remembered a couple things might help others along.
-the 90* coolant hose I used behind the exh. pipe is from the 250's head and trimmed to fit
-original exh springs were way too short, so went to my (then) near by ohv shop and found some that worked off of a yamaha rino (i think). pretty tight still, but didn't find anything closer.
P.S. after mocking everything up etc. etc., make SURE you lock-tite all of your engine mounts. St. Anthony's got a little more iron somewhere out in her dunes...
yeomans:
--- Quote from: Suva on April 07, 2012, 12:27:33 AM ---In the interest of fitting a larger capacity tank, I read in a post ( http://www.kxriders.com/forums/index.php/topic,8211.0.html ) that Flying Hawaiian used a 05-07 tank for better fitment on his '04. KXer asked how well it might fit on a 01, but F.H. didn't know... Anyone ever try mocking one up? Seems like there are very few Kx's in my neck of the woods to compare with- weapon of choice tend to be Katooms and YZs with some CRs. If no one knows an I can't find anything to check against, might go ahead and order one with the hopes of returning it if it's a complete no-go. Would really rather not order blindly though.
Sounds like the clark has the hands up vise IMS, anyone have a differing opinion?
--- End quote ---
I chopped the oversize clarke tank for the 99-02 kx 250 up to accommodate the larger head of the 500.
Took the tank to a plastics guy in town. He determined what type of plastic the tank was manufactured from. He was able to weld a new piece on the bottom of the tank.
I would say I only lost about 1 to 1.5 litre capacity in doing this. Fits perfectly now.
If you'd like some pics for ideas, give me a shout.
Suva:
NICE!!! Now that I'm out in "desert(ish)" country and only hair & hound type races around, thought I was going to have to buy another 500 so I could get a big enough tank. pictures would be awesome!
yeomans:
Having some trouble posting photos now for some reason?
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