Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2003 KX 250 SF Conversion
zz3gmc:
Did you use the standard mounting hole by the steering head? My tank is spaced up slightly. I made a short extension bracket and bolted it to the existing mounting hole which let me mount the tank flush with the frame and forward. My lower radiator mount is moved forward about an 1/8" to provide clearance by the head for the bottom of the radiator tanks. If left in the stock position the tanks hit the head. Ill be putting the bike back together (after a loooong 2 year rebuild) so Ill try to take pics.
sandblaster:
Wow!
Very nice work.
Somehow I missed the questions on the cases..
Sorry about that...
umberto:
--- Quote from: zz3gmc on January 30, 2017, 11:12:18 AM ---Did you use the standard mounting hole by the steering head? My tank is spaced up slightly. I made a short extension bracket and bolted it to the existing mounting hole which let me mount the tank flush with the frame and forward. My lower radiator mount is moved forward about an 1/8" to provide clearance by the head for the bottom of the radiator tanks. If left in the stock position the tanks hit the head. Ill be putting the bike back together (after a loooong 2 year rebuild) so Ill try to take pics.
--- End quote ---
I did have to redo my top mount with a small bracket, but it fits down pretty close to flush in the back. It clears the head and everything else really well now. Thank you for suggesting the Clarke tank, it saved me a lot of work and expense with plastic welding.
umberto:
--- Quote from: sandblaster on January 30, 2017, 01:12:42 PM ---Wow!
Very nice work.
Somehow I missed the questions on the cases..
Sorry about that...
--- End quote ---
Thank you sandblaster! No worries on missing the question, I know you've been busy.
umberto:
I got the oversized tank to fit, but there were a couple of areas that concerned me and I kept remembering that zz3gmc told me that he had to center his head stay mount in order for the tank to fit. I decided to tear Goliath back down and center the head stay to gain more clearance by the petcock area. It was about a four hour project, but it was really worth it as I gained some clearance behind the petcock. In welding class I had previously cut the stock head stay back, shortened it, and put a piece of plate in to connect the two halves. I did not move it from the stock offset location, which is about 1 1/2 inches off the shock mount. I moved it over today to be in line with the shock mount. Much further the other way and it would hit the other side of the tank.
My welding is a little crude, but I tend to over stick the items and then grind them back a couple of times until only looks like a fifth grader (not a first grader) welded it. :-D If you are building a conversion on this chassis, I would highly recommend doing this from the get go. It will save you a ton of work down the road.
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