Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2003 KX 250 SF Conversion
umberto:
--- Quote from: motopunk on July 22, 2015, 05:58:04 AM ---rob is the man with the right knowledge to the kx250 - R - frames 03 and 04 .. its an interesting fact with the airboxes ... 8-)
meanwhile a pic of my modification on the 86 motor that i sqeezed in the 93 frame .. intake itself is a brandnew 87-2004 kx500 intake boot... the airboot is oem kx250 1993 ... i had to lean it a little bit downwards to get the carb in the perfect position ...
maybe it helps a little bit for some inspiration..
... and lets see some pics of your progress... :wink:
--- End quote ---
I'll definitely take some pics this weekend. I'm using a 94 KDX 250 intake boot, 88 K5 reeds, 96 K5 air boot, 04 air box, and the 96 K5 filter and cage. I think it should work pretty well once I get the extra setback from the 04 air box.
zz3gmc:
I cut the plate to the shape of the flange or opening in the airbox. then bolted up the KDX250 intake, 500 carb and mounted the 500 airboot to the carb. Then I bolted the subframe and airbox assy onto the frame. I traced where the airboot pressed up against the plate, adjusting it accordingly, and cut the hole needed to fit the boot to the airbox. It was easier than I thought it would be!
umberto:
I got my 04 air box in today, and there is quite a difference in the two years. If you look at the photo below, you can see the area where I'm pointing with the pencil is set back 3/4" more than the 03 air box. That is all the space I needed to get the boot to fit.
I went ahead and made a template from the ring that clamps the boot to the box adding a little bit around the outside to seal the airbox. I kept testing it and trimming where necessary:
I then cut it out of aluminum sheet I got at Lowe's, sealed it with gasket maker, and added sheet metal screws for security:
I ran out of time today. I'll fit it tomorrow and hopefully get this dude buttoned up and ready for a ride report.
zz3gmc:
Pretty much what I did! Pretty easy isnt it!
umberto:
Yep, it was really an easy process. I can see now why it was so much easier on the 04 you did. The 04-07 air box has a ton more room.
I did notice a problem with the mounting flanges at the top of the air box. I'm going to repair them and then I can mount it up.
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