Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
2017 KX250F - 2004 KX250
umberto:
I was working on getting 2017 plastic put on my 2004 KX250, which involved buying the subframe, tank, and plastic from eBay. I recently sold a couple of my bikes, and have been wanting a newer bike for a while. Unfortunately Kawasaki has basically said screw two-strokes, so we are at an impasse. I figured putting new plastic on my old bike would be as close as I would get. In the process of buying the subframe and tank, I noticed that the guy had all the other components of the bike as well. He said to contact him directly if I needed anything else, so I called him and inquired about the frame, swingarm, triples, and linkage. He offered me a deal I had a hard time refusing, so it looks like I am off on an aluminum frame project. I haven't had a new bike in 26 years, so I pretty excited about having the latest and greatest.
I spoke with Fl_sharpshooter about his project, and felt pretty comfortable with the project until I got the frame out of the box yesterday. It looks like Kawasaki changed some of the design of the frame. The y in the frame is now part of a larger piece that extends up to the steering stem. This obviously negates the ability to grind away the weld and remove the y for re-positioning. I guess at this point I am going to have to cut the frame and add something inside (like the old y joints had the solid tab that went inside the frame) and outside the y (plate weled onto the frame?) to reinforce the joint. Anyone have any thoughts on if I'm on the right track? I only get one shot. :-o
KXDINO:
sounds good umberto , you will succeed , but i think you should punch out half a dozen frames and sell the rest , i have a 01 250 engine looking for a home , and the 17 are great platform , and when it completed you could show the out of touch japs this is what you should bring out. :-D
FL_Sharpshooter:
--- Quote from: umberto on June 23, 2017, 04:25:21 AM ---I was working on getting 2017 plastic put on my 2004 KX250, which involved buying the subframe, tank, and plastic from eBay. I recently sold a couple of my bikes, and have been wanting a newer bike for a while. Unfortunately Kawasaki has basically said screw two-strokes, so we are at an impasse. I figured putting new plastic on my old bike would be as close as I would get. In the process of buying the subframe and tank, I noticed that the guy had all the other components of the bike as well. He said to contact him directly if I needed anything else, so I called him and inquired about the frame, swingarm, triples, and linkage. He offered me a deal I had a hard time refusing, so it looks like I am off on an aluminum frame project. I haven't had a new bike in 26 years, so I pretty excited about having the latest and greatest.
I spoke with Fl_sharpshooter about his project, and felt pretty comfortable with the project until I got the frame out of the box yesterday. It looks like Kawasaki changed some of the design of the frame. The y in the frame is now part of a larger piece that extends up to the steering stem. This obviously negates the ability to grind away the weld and remove the y for re-positioning. I guess at this point I am going to have to cut the frame and add something inside (like the old y joints had the solid tab that went inside the frame) and outside the y (plate weled onto the frame?) to reinforce the joint. Anyone have any thoughts on if I'm on the right track? I only get one shot. :-o
--- End quote ---
Looks like you've got your hands full. Just try to take it 1 piece at a time, it can definitely get overwhelming. The y-piece looks really low on the newer frame. I would seriously consider looking for or making a total replacement y-piece, I can see the radiators are going to give you a fit too. Not sure how tall the 250 engine is, but looks like you're going to have to extend the cradle too.
umberto:
Thank you for the votes of confidence. I have been having multiple "what have I done?" moments the last few days. Earlier I was thinking about Sandblaster's AF project that used the cradle from a 2001 CR 250 two stroke. I think that may make the most sense, as it will give me the higher Y piece with the rails already attached. That way I just have to worry about trimming and adjusting as necessary. I think the picture angle is misleading, as there is more room in the frame than it looks like. I think the 250 should fit just fine. If I was going to do a 500 that would be a deluxe wrestling match.
I'm going to use the two stroke radiators if possible, so the mounts will need to be redone on the bottom anyway. I think that would be easier than trying to put the much larger four stroke radiators back on.
I grew up working on hot rods with my dad, so I'm used to making stuff that isn't supposed to go together work. I guess I need to just remember this advice:
umberto:
I measured the frame from the swingarm bolt straight forward, and it was almost exactly the same measurement as my 04. I think I'll be good on space.
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