Maintenance & Technical > KX500 Steel Frame Conversion (SFC)

my 03 kx 250/500 build

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jrowley85:
thanks for the info Hawaiian!! well then since thats settled was the build on the 04 as simple as the builds i have been reading abouton this site with the 99-01's?? and i already have a great running 99 kx500 that i fell into when a guy wanted to trade it for my 01yz250... i think i got the better deal :-D.. the problem im finding is the 250's are just so d**n expensive, its a good thing im in Afghanistan right now or i might get impatient looking for the right bike.. also what kind of mods did you need to get that service honda exhaust to work?? i have been to there site and i cant even find where they sell them, and i know i would not want the Q silencer... i like being heard!!!! do you know of any good sites to look for bikes other that craigslist?

The Flyin Hawaiian:
From what it looks like it seems to be about the same amount of work to do either one. The headstay has to be centered on the 03/04 frame for tank/petcock clearance. The headstay mount on the head needs to be shortened and a new mount hole drilled. Everything else is more or less the same. The pipe pretty much bolts right on. I clearanced it slightly to clear the coolant hose better on the right side of the cylinder. I didnt alter the pipe just so it can be replaced easily. The 03 frame already has a rear mount for the stinger. The 04 frame doesnt and needs to be welded on. I welded a mount to my subframe. Its been over a year now and it hasnt had any issues, very reliable and handles great! Took a little while to get the jetting straightened out and fine tune it. If you have to run a big tank you need to use a 05-07 KX250 2stroke tank. The 03-04 IMS/Clarke tanks will not fit. Same thing with the 03-07 KX125 tanks, they are the same as the 03-04 KX250 tank.

jrowley85:
WOW!!! your a wealth on knowledge!! i cant wait to get this project started!! I will be going to you for input since you know so much if you dont mind? im an alright welder for what needs to be done, but how hard is it to get the head stay cut and bead blasted?? is that somthing i should just send out to someone?

The Flyin Hawaiian:
Sorry for the late reply, I just saw the post. I had a machinest friend cut the head-headstay down and redrill it.

Ims Roll:

--- Quote from: jrowley85 on July 19, 2012, 04:11:15 PM ---thanks for the info Hawaiian!! well then since thats settled was the build on the 04 as simple as the builds i have been reading abouton this site with the 99-01's?? and i already have a great running 99 kx500 that i fell into when a guy wanted to trade it for my 01yz250... i think i got the better deal :-D.. the problem im finding is the 250's are just so d**n expensive, its a good thing im in Afghanistan right now or i might get impatient looking for the right bike.. also what kind of mods did you need to get that service honda exhaust to work?? i have been to there site and i cant even find where they sell them, and i know i would not want the Q silencer... i like being heard!!!! do you know of any good sites to look for bikes other that craigslist?

--- End quote ---
try "bikefinds" if you don't mind driving near by you will probably have way better luck finding one. found my 01 K5 on bikefinds. had to drive 8 hours none stop but oh well

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