Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2003 KX 250 SF Conversion
umberto:
--- Quote from: KevinTwoStk on May 27, 2015, 08:09:06 PM ---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.
--- End quote ---
That's a relief, that sound was freaking me out. I've always used Magura Blood as well. I'm like you, why take the chance?
umberto:
I made some progress on the bike today. I built a platform to hold the engine level and leveled the drill press as well. The hole drilled cleanly and quickly. Whew!
While I was doing the drilling, my 15 year old son stripped the bike down to pretty much nothing. It makes you proud to see your son using the things you've taught him. Here's a picture right before he pulled the swing arm.
After some fiddling, I was able to get the motor in the frame. I went ahead and cut off the front motor mounts and trimmed back the head stay so they would be ready to weld. I just need to trim the swing arm bushings and install them back in the already trimmed swing arm to have her rolling and ready to pester my welding class instructor for advice. :-D
zz3gmc:
Looks like the 88 engine has more room for radiator clearance due to the lack of the 3rd powervalve that the 89 up engine has. I cut the lower rad mount off of my frame and moved it about a 1/8th" forward so the radiator tank doesnt touch the head. I removed the clutch cover and basket so the engine had a flat surface to rest on. I had my machinist buddy open up the pivot hole. The next one I build I'll do it myself. Lookin good!
P.S. If you decide to get rid of the 03 forks let me know! When properly revalved they are the best forks Ive ever had for offroad! I swapped a set onto my 07 250, 04 500 hybrid and my wifes 04 300 big bore. With a set off Flexx Bars and 03 forks it will eat up rocks, roots and all sorts of trail junk!
umberto:
I was so nervous drilling that hole out that I leveled everything in site, including myself. :-) I used the all thread and the nuts to allow me to adjust the motor up and down to level everything. It was a lot easier than I thought, you're really just drilling a little bit on both sides not the entire hole. The motor went in the frame really easily too, once I took off the two 90 degree elbows for the cooling system. Lord knows I took it in and out enough times yesterday as I fiddled with stuff. I'm pretty excited to get it back into a roller so I can start fitting the exhaust. I know I have a ways to go before I'm done, but it was nice to get the first steps out of the way. I'll be ordering some goodies this weekend to start redoing some of the hard parts.
I'm thinking about sending the suspension to Race Tech. The forks are leaking, and the shock is in major need of a rebuild. I had my 07 suspension done by Factory Connection and it really turned out well (it ended up on my 04), but I wanted to try a Race Tech re-valve with the gold valves. Does anyone have thoughts on which one is better?
umberto:
Made some more progress today. I was able to get the swingarm and swingarm bushings trimmed down and installed. I left everything a little big and then slowly fine tuned it using my belt sander. The swingarm moves really easily, and the chain is in perfect line. I am going to replace all the bearings, and the rear end should be good to go. I'm pretty excited to have it this far. On to the exhaust and motor mounts!
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