Maintenance & Technical > KX500 Steel Frame Conversion (SFC)

my 03 kx 250/500 build

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Suva:
You didn't have issues with the tire rubbing it?

The Flyin Hawaiian:
Nope, everything clears.

Suva:
nice

jrowley85:
first off i love this site, lots of good info, but to get down to business :mrgreen: is it better to try and find a donor bike? or to piece one together off of ebay?? ive been looking and cant seem to find a bike thats not way to expensive considering what im going to do to it :evil:... and if i do piece one together how much of my original 500 can i use? i know i can get a frame, shocks and all that for a decent price but the rims are just way to expensive, might as well buy new! also i have heard of a few guys using the stock 500 swing arm, is that a good way to go or not?? will it even bolt up with the 250 linkage?? as you can tell ive never built a 250/500 conversion before.. thanks for the help

The Flyin Hawaiian:
I lucked out and already had the 250. The 500 fell into my lap after my brother inlaw lightly seized it and wanted to trade me even up for a DR350/435 dualsport that I had. I probably have around $500 into it after selling off the 500 chassis. Still have a few bits left that should knock it down to a couple hundred. Again, I was very lucky. I only used the engine, ignition and a few miscelaneous bolts and brackets from the 02 500. Everything else was from the 04 250 with the addition of a 96 KX125 carb top and cable. 91-94 KDX250 carb intake and the Service Honda KX500AF exhaust and FMF Q silencer. I did use the 500 throttle. The easiest way is to have both bikes and not sell off anything until the project is done. Ive seen 03 250s for as low as  a grand and the 500s run from $800 to $4500. I wouldnt use the 500 swingarm, it would most likely change the leverage ratio of the shock. It wont even come close to working on a 04 250 due to a change in the linkage arrangement for that and following years.

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