Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2001 RM250/ 1994 KX500 conversion. The "Kawasuki RM500"
mikectanker:
Got 1/2 of my homemade 2tall kit done today.
I had some 2 inch diameter pipe and cut 2 3inch lengths.
Cut 1/3 of the pipes so they were U shaped to sit on top of the original frame backbone.
TheN used a 1x2inch piece of rectangular tubing for the rear of the tank to sit on.
I only have an old buzz box stick welder. I sucked at using it but luckily someone I know stopped by and made it look easy. Put the stock rubber pieces on top and it fits real nice.
I will use the stock mounting bolt hole on the frame for the gas tank. I used two pieces of 1.5inch mounting angle from tractor supply in place of the stock angled brackets. .
Now I just need to get the sub frame welded with 4 1 inch drops and extend the silencer mounts 1 inch.
This will also result in tipping the top of my carb forward allowing more room so maybe I can slip a vforce in there. I have a 125 air boot in case I need a little more reach but don't think it will be needed.
Also ordered a rear wheel from warp9. Just all silver parts. Really wanted green but then I would have to buy both wheels. The front wheel is really nice so I decided to save some money.
Can't wait to see how it rides with a better clutch pull and ergonomics that fit me better.
Thinking about used pegs from a 2003 or newer bike since they will make more room for my size 12.
The newer peg sat 10mm farther back. If that isn't good enough then the shifter and rear brake pedals will be chopped and extended.
mikectanker:
Clutch arm lengthened. Pulls a little better but I'm grabing a hydraulic setup used when I can.
Got to mount the 1 inch taller sub frame back up. I should have pics and a ride report by the end of the weekend.
mikectanker:
Here's the 1 inch lift kit/home made 2tall kit. Tank/shrouds and seat/subframe are all 1 inch higher.
The steel ruler represents the new path of my knee from having my knee straight above the foot peg to sitting way forward.
I can now glide along the line of green chrome without jamming my knee in the holes and screwing up my knee brace positioning.
mikectanker:
Here's how it was done. By no means is it a work of art, but it works.
3 spots where the tank sits on rubber spacers. cut some 2 inch tubing in the right spot so it was "C" shaped for a 1 inch lift.
then used some 1x2 rectangular stock for the bottom of the tank to rest on just like stock but up an inch.
Made 2 drop brackets in place of the stock black plastic mounts on the underside of the tank.
Added a key ring on the rubber strap....Hey it works and its hidden under the seat.
Top subframe mounts dropping down an extra inch
Right side bottom subframe mount (I gotta clean and trim that ugly crap up but it'll work for now)
Same thing on the left
Silencer mounts from both sides
mikectanker:
Here's the extended clutch arm. Approx 5/16 inch added
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