Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2001 RM250/ 1994 KX500 conversion. The "Kawasuki RM500"
mikectanker:
Coolest looking throttle assembly ive ever seen on ebay. You guys think a green one will work?
http://www.ebay.com/itm/FOR-YAMAHA-YZ-100-125-250-MOTOCROSS-CNC-THROTTLE-GRIP-ASSEMBLY-MR-/321815898414?var=510742064803&hash=item4aedb8e92e&vxp=mtr
mikectanker:
Got the k5 motor sitting in the rm frame. used k5 swingarm bolt(will need to drill the cases later.
It is amazing how close the motor mounts all are to working!
RM radiators are bigger than the k5 ones and will work easy enough.
airboot is almost a pefect fit with no mods needed.
electrical parts are bolted up in stock rm locations. no mods needed but ill make it nicer later.
I need to...
-post pics (plenty of detailed ones on my phone)
-heat and dent the frame where the front lower ignitioncover bolt is hitting and possibly re-enforce the underside of that spot.
-have the professionals drill the 43/64 bit through the cases
-line up the sprockets and shim at the swingarm.
-then set the other mounts right and shim.
- will need a new head stay with shims.
- need to move the radiators forward a hair(they are hitting the top front of the motor but bolt up)
-need to make a short 90 degree coolant elbow
i can use 1 k5 hose on the Right radiator. RM hose on the left with a elbow and small hose going to the dome.
-need to mold the tank(hitting water spout on left top of dome)
should i use hot water or my heat gun?
-need to make service honda kx500af pipe fit and then match the muffler to it
Am I forgetting anything important?
umberto:
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
mikectanker:
Thanks Umberto.
Turns out I had a photobucket account from 6 years ago with 1 pic. Forgot it existed.
Should have pics up tonight I hope.
Gotta heat and smash that framerail by the front ignition cover bolt.
Do any kick start levers with more of a forward bend fit on the k5 engine?
mikectanker:
Just ordered more parts all from ebay but 1
-2 PIECE CLUTCH COVER ADAPTER from sandblaster $95
-New oem KX450 clutch cover $45
-KX450 clutch cover gasket $8.86
-KX500 clutch gasket $7.99
-wiseco topend kit $171.79
-fmf muffler packing $11.39
-spec bolt 120 piece RM kit $29.99
-Outlaw Racing Complete Replacement Seat $87.96
-Fusion Graphix custom seat cover (white top/green ribs/green sides) $59.99 not from ebay, but fusion's website
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