Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
2003 RM250 /KX500 conversion
510rider:
Picking up my rolling chassis tomorrow!!! Let's get this party started!!!
mikectanker:
if you don't find an answer in my build thread, don't hesitate to call me. I check the site a few times a day sometimes. then other times I'm working so much I can't check it for weeks. I drive trucks so I can almost always bs on the phone to help out.
510rider:
Thanks!!! I certainly will be in touch.
FL_Sharpshooter:
--- Quote from: umberto on February 08, 2017, 05:38:52 AM ---Honestly welding one wasn't too bad. You might try flipping the water inlet over and using a different hose. That transfer is where the pipe meets the most interference, and flipping it seems to help. It looks like this:
That's FL_Sharpshooter's bike, maybe he can comment on where he found the hose for it.
--- End quote ---
The hose kit that I used is the service honda kx500af kit. You can find them on ebay; they're not cheap, but my conversion went smoothly because of them.
--- Quote from: umberto on February 07, 2017, 01:45:42 PM ---I used three pipes on mine (2 CRs and one KX), but in hindsight I could have gotten by with the two pipes. Use the KX sections until it begins to turn the corner, and weld that to the CR section back to the silencer. Look at the AF conversion FL_Sharpshooter did, I think that is how he did his pipe.
--- End quote ---
In my case, I just used a kx500 pipe and cut it right when it started to angle out of the exhaust port and wrapped around the frame. I then welded the cr500 pipe to it, I did have to bend the bottom mounting tab in my vise a small amount. I also cut the "tail" off the pipe, and rotated it; I also had to bend in the tail a small amount. I also rewelded the tail end mounting piece so that I could run the silencer in the stock kx450 location (that way it's cleaner behind the number plate). In order to run it in the stock location, I had to extend the tail piece out, so I subbed in the same gauge thickness of metal, it worked out nicely. The way my pipe mounts is really similar to a ktm 250 mount. It was a bit of a headache, but I think I could do it much faster if I had to do it a second time.
510rider:
First set back.....the flu! Didn't get my roller yet.
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