Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)

Frame question for a 250af build

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funke93:
Hey guys been quite a while since I last posted... Sold my kx250 roller on here and started a different build... A zx10r that loved taking my money more then any girlfriend I've ever had! Now that I am finished up this bike and getting ready to sell to help pay for schooling, I've gotten an itch and this particular itch involves a partially complete bottom end for a 99-02 kx250 that's been in my basement since the fall of Rome. Now this would be my third kawi and Ive always wanted a AF built bike that I have done myself. Now question for you guys is the 450f or 250f a better platform to start on and why which years have the most interchangability? 06-11 kx450f I've been told? But also heard the 06 has stink bug suspension. I've been lurking for quite some time reading up on all the 250af builds just figured I'd finally spill my guts. (:

don46:
I would use the 250f chassis for a 250, the cradle area is a bit more compact on the 250f. and I would use the 250f Showa components on either frame. The last 500 af I built I used the 450 frame and the 250 suspension, in fact many serious racers are doing that, they bolt right up, gotta have the triple clamps as well for the 250f. I did one of those builds a few years ago for my wife, I used a 06 motor, realized it was to much for her so I peddled it. I do think the 01 motor is a bit tamer and easier to ride so it should be good

funke93:
Hey don! Thanks for the response, I have read some of your posts on suspension remember reading not to go with the kyb's and use the showa's instead. The Showa forks are on the 06 to what year and only the 250f forks right? I heard the 06 450f suspension isn't that great are those Showa units as well? Why wouldn't you want the extra space that comes with the 450f frame? Are there and issues with the gas tank to spark plug spacing when using the 250f frame. Also which year 250f frame should I look for, I'm not the type the always believes newer is better. Also since I'm saving to leave for school and finish up my degree away from home starting next semester this build will take awhile. Also the kx250 motor I'm going to start building I heard you can use a 91-94 kdx250 6 speed tranny in the cases with the use of collars on the shafts is this kind of tranny good to use on a mx track as well as the woods? Thanks for any and all input guys!

zz3gmc:
91-94 KDX250 is a 5 speed. The 200/220 is a 6 speed. I believe the older air cooled KDX250s were 6 speed. There is a whole thread on the KDX trans conversion on Thumper Talk in the Kawasaki 2 stroke forum. A guy that goes by the name No1Clyde is the guy that has done it. The 200/220 trand wont fit the 250.

funke93:
Yes, I read No1clyde's post on the tran's swap very detailed I guess I just missed the part where the kdx250 tran's is only a 5 speed, and just assumed since it was a kdx that it had 6 speeds? Why do people do this swap then more woods friendly? Why don't they just take the shorter first gear from the 94-96? Kx250 don't quote me on those years haha

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