Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
07 KTM 250sxf/500kx conversion
hunter:
Small Update:
Things are finally moving forward, Got the hole reamed out last weekend and got the engine in the bike to get a rough idea how things are going to fit. I lucked out and got this Saturday off and was able to get a welder/fabricator to work with me on it to get the Mounts done, pipe fitted w/mounts along with modifying the left radiator. Pretty much all welding done.
Issues that need to be addressed that are obvious and appear to be a common issue:
Stator cover hits the left frame cradle
Kick starter hits the frame as well
250sxf air boot appears to might be able to work
Where is everyone mounting there coils and such?
Anyways should have some pictures to post up after this weekend of some progress.
hunter:
Heres a few pictures of the progress. Also some things to note that I somehow never even noticed that should have smacked me right in the face. Front and bottom mount holes were previously reamed out to 12mm and were filled with gasket maker to make what I assume is a make shift rubber mount. I bought M12 bolts for the mounts but I do plan to find some with a Allen head. Mounts were fabricated up and bolted on to the engine and then everything was tacked including the nuts. Then engine came out and the mounts were finished off. My sprockets were aligned with the engine pushed all the way to the left against the swingarm. A 6mm wide spacer will be needed and I already have that made up and on hand. I did not modify the frame where the stator cover hits, we just shimmed it in that spot for clearance. I know things will be tight around the spark plug area so I ordered some shorty spark plugs and the NGK short plug as well. Kicker will have to be massaged a little bit as well for it to kick freely.
Also picked up another KX500 engine today, was told it was a 86 and the cases are in pretty bad shape. Rear pivot hole was attack by what appears to be a Die Grinder and a inch or so has been removed of the right case mount hole. The hole was also reamed out to god knows how big and most likely not square.
BYE BYE KTM mounts
All done
hunter:
Some more progress, slowly coming together.
Mounted radiators - Left radiator needed the bottom spout spun 180deg upwards
Also on the KTM they have this T inside the frame that is integrated into the cooling system. I did not need the bottom part of this T, so we took it apart. I used a m20x1.5 oil drain plug from the hardware store to plug the hole in the bottom of the T. We had to cut off head and make a slot for a flathead screwdriver to fit to screw in our makeshift recessed plug. Reinstalled the Top part of the T in the frame and it will now act as the cross over From Left to Right.
All the Exhaust mounts are done, just need to get a small piece bent up to mate the silencer to the headpipe.
Mounted up the CDI and Coil, just reused the factory KTM locations.
For a Intake boot I used a 2008 KTM 250 SX 2 stroke boot, DO NOT put the boot in first. You have to mount the carb to engine then put the boot in and mount to the carb before trying to install the boot. Doing this, allows the boot to take on a new shape after installed and fits like a glove....you will cuss a bit trying to get it installed lol.
reklessj:
Looking good man, she is coming along nicely!!!
umberto:
Great looking bike, you've made some great progress so far. How close are you to riding it?
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