Maintenance & Technical > KX250 / KX125
Installing 2017 KX 250F plastic on my 2004 KX 250, 2003 250, 2005 125
umberto:
The subframe and tank shipped today, and eBay is estimating a Thursday delivery. I did see one issue with the mounting that I will need to address. The 2017 subframe mounts from two sides with individual bolts that thread in to the frame, while the 2004 used one bolt that screwed into the other side of the subframe. I am trying to make the conversion bolt on, so that I can switch back to the 2004 plastic if I don't like it. I have an idea on how to make it work, but I will need to get everything in my hands first. Here is what I am talking about with the mounting:
KXDINO:
i heard the 19 kx450 is a whole new bike so i gather it will have fresh plastics on it , you might want to put the 19 stuff on your k5 umberto to bring it up to date . :-)
umberto:
I can do it. I still have the 500, a 250, and a 125, so I should be covered for a few updates. :-D
umberto:
I got my plastic, seat, and air box ordered today. The air box is back ordered, but the plastic and seat should be here by Friday. That should at least let me set up the subframe and plastics. eBay updated to show the subframe and tank getting here on Thursday. Saturday is shaping up to be a fun day in the shop!
umberto:
OK, so I got most of the parts in (the airbox halves are still on backorder) and was able to start the mock-up. I started with my 2004 KX 250. First thing I did was to remove the plastic, gas tank, subframe, and exhaust.
It took a little sanding on the left side, but I was able to fasten the subframe and the top and left:
The gas tank slips into the frame rails, as long as you remove the two rubbers on the sides. The back ones appear to be on the frame in the PC pictures, so I left them. More on the tank in a second:
So at this point I am feeling pretty good about the whole process. That was until I tried to mount the long piece of plastic on the left side. The radiator scoops were too far back to catch the side number plates. It was about an inch too far back. I switched gears a little bit and mocked up the right side of the subframe so I could at least test the fit of the seat and see if it was in spec. I used a little bit of aluminum strap; the final piece will be 1/4" aluminum and will require a bit of welding. I didn't have any 1/4", so I decided to just mock up so I could continue on with the fitment.
Mounting the seat confirmed that it was at least an inch too short. I think it may have something to do with the tank being too high in the back, so I may need to do some heating. I tried to remove the bolt at the front of the subframe and let it rotate back, and I was able to get everything to fit.
The tank should be able to come down about an inch before it hits the subframe, so I think I may be able to heat my problems away. As you can see in the second picture, the tank on my bike rides out from the frame more than the PC bike.
Tank clearance:
Frame Clearance:
Anyway, that's day one. I think this is doable, it's just going to take some work. I'll keep you guys posted.
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