Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2003 KX 250 SF Conversion
umberto:
Thank you reklessj! I plan to attack the physical therapy and get as close to 3 months as possible. I can't have the surgery until late July, and I really need to be ready for Christmas season at the store.
umberto:
Today is one of those days that is torture if you can't ride. High 80s, low 90s, but pretty decent breezes. I repaired all the crash damage to Goliath (broken clutch perch, front end was a bit tweaked), and updated the look a little bit with the green side plates. I also added the Pro Circuit fork decals I got from Australia.
Ugh, I wish I could ride this beast...
umberto:
The KYB kit forks that are on Goliath have always been a point of concern with me. The 2003 triple clamps bottom out when tightening on the forks, and I don't think they are getting a good bite. I tried contacting Emig racing to see if they still had the triple clamps that Pro Circuit used back in the day; they didn't carry them, and they wanted $800 to do a custom set. Undaunted, I busted out the old trusty calipers and Sandblaster's awesome interchange list and was able to determine that the 2001 triples are exactly the size I need for the forks (the Pro Circuit forks are 46 mm, but larger than the earlier 98 models forks they were meant to replace). I got a set of the clamps, and bingo they fit great on the forks. The only issue I have is that the steering stem on the 2001 is shorter than the 2003. It looks like the stem from the 2003 is the same size in the clamps, so I should be able to press it into the 2001 lower triple. I have never had to press out the triple clamp stem, so I wanted to see if anyone had any tips or tricks. I watched a video on Rocky Mountain and it seems pretty straightforward, but I figure it's cheaper to check with you guys first. Anything I should watch out for? My father has a 30 ton shop press, is that sufficient to accomplish the job?
Thank you!
umberto:
I got the steering stem pressed out of the 2001 triple clamps and pressed back the 2003 stem. Very easy process with the right tools and a press. I used this video as a reference:
https://www.youtube.com/watch?v=2R92wxhc4_E
I bought that Park Tool they recommended and it worked like a champ. Once I got the bearing installed, I installed the clamps on the bike. The new clamps get a very good grip on the forks, which is comforting because I'm pretty certain that the forks turned in the clamps when I hit the concrete chunk causing the big wreck.
I have an issue with the non brake fork lug threads being stripped, and I still need to fit the front number plate, but another ride report should be coming soon.
umberto:
I am happy to report I finally got the carb tuned correctly. You can roll the throttle on from any gear and rpm, and it just pulls. I ended up coming in two more full turns on the power jet. This motor is stout, but really manageable if you treat it with respect.
With the triple clamps sorted, the kit suspension is perfect for the bike and I am really starting to love riding this bike. I'm at my parents this weekend, so I'll try to get a ride video together tomorrow.
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