Maintenance & Technical > KX250 / KX125
Installing 2017 KX 250F plastic on my 2004 KX 250, 2003 250, 2005 125
umberto:
I had a chance to look through the instructions, and it is really well thought out. It would be hard to recreate all the pieces (the seat and airbox filler piece especially), but at the price they are charging for everything it wouldn't make sense to try to recreate it on your own.
umberto:
I decided to put this plastic kit on my 2003 conversion. I detailed the installation here (scroll towards the bottom of the page):
http://www.kxriders.com/forums/index.php/topic,14629.315.html
Bottom line is that this is the kit to buy. You won't be sorry.
umberto:
When I was building my 2017 conversion, I had an issue with my airbox spacing. I found a guy making kits similar to the Pro Circuit kit, but with 3D printed airbox spacers. I wanted to buy a single spacer, but he wasn’t interested in just selling a ring. I finally got him to agree by buying a kit. I haven’t done anything with the kit, because I needed to buy some parts to make it work. I had the stock tank from the 2017 conversion, and I managed to find a stock subframe for cheap on eBay. Everything else was OEM or aftermarket, so I’ve been slowly collecting parts. My son upgraded to a 250, so I decided to put the kit on his old 125. Unfortunately the kit did not come with instructions, and the company is no longer making the kits [edit 6/30/19 they are still offering the kits on eBay]. It took me a couple of Saturdays to figure it all out, but I think I finally got it where I like it. The kit comes with a couple of brackets to mount the subframe. One goes on the left side of the bike, and uses the subframe mount and the chain roller mount to locate a bracket for the new subframe to bolt to (picture 1). The other uses the shock mount and top subframe bolt to mount two new brackets that the top of the subframe attaches to (picture 2). In this picture I had the spacers installed incorrectly. The right side bolts directly to the bracket, and the spacer goes on the left side. I’ll post some pictures of the airbox spacers in my next post.
umberto:
The kit came with a bunch of non metric and low quality metric bolts from Home Depot or Lowe’s in sandwich bags, so I’ll definitely be making a couple of trips to the Fastenal store for final assembly, but I managed to use them for mock up. The two 3D printed rings required some light re-engineering, but I managed to get them mounted, and they bolted the airbox right up to the carburetor (picture 1). I think that was the hardest part, so I’m relieved it worked. My last hurdle is the seat. I used the base from an Acerbis X Seat, but it’s not stout enough to really work. I’m going to try using some additional ABS I have to reinforce it. If that doesn’t work, I guess it’s a stock seat if I can find one.
All I have left from here is the radiator attachments, posts for the front number plate, and a silencer mount.
umberto:
I got a lot of work done on the 125 that doesn't really reflect the hours invested. It still kind of looks the same, but a lot was done under the hood. The first picture is how the bike sits right now. I did go ahead and switch to a black Acerbis soft X-Seat. I like it a lot better than the original green regular foam X-Seat. I think you could actually sit on this one for more than ten minutes. I also fabricated a new gas tank block off plate, as the one that came with the kit used bolts with nuts to secure it and I didn't feel like it would seal very well.
Once that was done, I sealed the airbox, torqued all the bolts on the subframe, and got the bike ready for the plastic to go on. I breezed through all that, and was really having a great day until I got to the air filter. It's simple to mount, right? Not this one. The 2017 airbox does not have guides for the filter cage (unless I missed them on the parts fiche), and the element holder has to be really pushed towards the cage to get the bolt to catch. It took me a good 30 minutes to figure out that the element holder just needed to be pushed in and that I didn't have the thing in there wrong. :-D
Once I got that all squared away, I made a mounting bracket for the radiator shrouds, and that's as far as I got. Next up is the silencer. It is coming out at a too steep angle, so I'll need to relax the angle and have it rewelded. After that, it's on to a few small cosmetic items and it's time to take it for a spin.
Navigation
[0] Message Index
[#] Next page
[*] Previous page
Go to full version