Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2003 KX 250 SF Conversion
umberto:
zz3gmc gave a lot of great info on doing this swap. You do need to trim the swing arm and bearing sleeves, but thankfully the motor mounts line up at the bottom and with the swing arm pivot, so you just measure and trim. Another great tip he gave me was to use a 2005 or later tank. The heads on the later models sat more upright, requiring a more shallow tank. This helps a lot with the obviously taller K5. Thank you zz3gmc!!
umberto:
--- Quote from: KevinTwoStk on May 24, 2015, 06:47:43 PM ---Good deal! That's a nice looking '03.
I can't speak for the Magura hydraulic conversion on a KX500, but I do have one on my '00 KX125. With all the clutch abusing required to ride a 125, I think it's a pretty good barometer for the Magura system.
I've had zero troubles with the slave cylinder, but I've had to replace the seals a few times on the master cylinder. As for performance, it's everything it's supposed to be: self-adjusting, easier lever pull.
Motocross Action featured a KTM/KX500 that used a Magura hydraulic conversion. The 250SX uses a Magura master cylinder, so they just added the KX500-spec Magura slave cylinder. I assume it worked well.
--- End quote ---
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Thank you! It was a long drive to get it, but I think it was worth it. The motor is very nice, and the bike is in great shape. I'm going to be selling the motor so it was the most important part to me, but the rest of the bike should clean up well.
I have had a weird issue with my slave cylinder. It was making a weird sucking noise when I got home. I assumed it had a blown seal and it would quit working at any time. After a bit it stopped and the clutch still works very well. It was raining pretty heavily when I went to get it, so maybe it was water that was being forced out from around the seal. Has anything like that ever happened to yours?
zz3gmc:
You can use the stock 03/04 tank. If a big tank is needed then use the 05-07 KX250 Clarke/IMS tank.
umberto:
Gotcha. Do you need to heat and bend the stock 2003 tank to get it to fit?
KevinTwoStk:
My Magura slave cylinder makes the same noises you're describing after I wash the bike or anytime the slave cylinder gets wet. I wondered about it, too.
I've always used Magura Blood mineral oil in my clutch system. I've heard you can use common mineral oil from the drugstore but have never tried it--likely never will.
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