Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2001 RM250/ 1994 KX500 conversion. The "Kawasuki RM500"
mikectanker:
I cant seem to find new vforce 1 replacement reeds. any help out there?
mikectanker:
--- Quote from: umberto on August 22, 2015, 04:29:38 AM ---You can reshape your tank using boiling water. I boiled water in my wife's two soup pots and then poured it in the stainless steel sink in our utility room. I put the tank minus the petcock (I built a little aluminum plate and used a bit of floor mat to block the opening off) in the water for 2-3 minutes to heat up. It becomes very easy to shape, but I would use a tire spoon or something metal to push on it because it was a bit too hot to use your hands. The boiled water will cool off pretty quickly, so I would have it marked and a general idea of how much you need before you start. Once you like where it is, run some cold tap water over it, and you're done. It's actually very easy and seemed really safe. Just like forming you sports mouthpiece. :-D
As far as the radiator mounts, I just welded up the holes and then marked a spot forward about 3/8" and drilled and tapped it. I made new radiator braces out of aluminum to keep the radiators pushed forward just a little bit. Don't push them forward too much or the hoses will kink.
Here's a link on how to post photos using photobucket. I can't wait to see pics; it sounds like a very interesting build!
http://www.kxriders.com/forums/index.php/topic,10040.0.html
--- End quote ---
Tried molding the tank with water tonight. I didnt get it to budge... the bottom of the tank hits the water spigot on the head.
this suzuki tank is pretty dam thick right there. I didnt get anywhere with my harbor freight heat gun either, but I'm afraid of burning the tank with the heat gun. I havent found any detailed tank molding tips on here.
I've got to figure something out, or just pay to fab a one off 2tall kit.
Used tanks are cheap enough, and Clarke's website says they will make a new one in black.
Here goes... gonna heat the crap out of it and if it fails get a new clarke and rip off the 2tall idea.
I like the new 2tall ripoff idea the best but dam that'd be expensive.
mikectanker:
After some time to think and measure and think some more. I'm going to make my own 2tall knock off kit.
Ordered an RM125 air boot which reaches farther. Got the other ideas on paper
It'll work one way or another.
Sold my 250 motor for $1050 plus shipping on ebay recently too. Bought the RM for $1400.
I pulled the adds for the Kx500 parts.. with the extra motor I'm considering making it an original kx 500 snow bike. It snows pretty good where I live around Erie PA but nothing like out west. That might be next year's project.
mikectanker:
Got the tank reformed with the heat gun. Heres the rough mock up of the bike. No 2tall rip off yet...
A few minor parts missing, gas tank not blacked out yet, frame needs painted, needs finished graphics........
A lot more pics coming soon
mikectanker:
Holds water after heat gunning. I used sockets with an extension to push on the hot plastic. Then held it there, set down the gun and hosed cool. gotta hose it or the tank just goes back
Right side
Left side
Right used kx500 hose just had to trim it a little
left side. 1 big and 1 small straight hose. used a brass 90 degree barbed elbow. brass elbow had to be cut a little.
Used this aluminum flat stock to move the radiator mounts on the frame up and forward a bit so the bottoms will clear the head.I will also be adding spacers for extra clearance side to side between the rads and head.will need 2 longer crossover hoses
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