Maintenance & Technical > KX500 Steel Frame Conversion (SFC)

KX250 Chassis With 500 Motor

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don46:

--- Quote from: gwcrim on May 20, 2007, 01:50:26 PM ---l have a question regarding this whole thing.  Really how much difference is there between a regular old 500 and a 500 in an '02 250 chassis?

I'm the kinda guy that likes stuffing big motors into small packages, but before I start down this path, I was just kinda curious as to what exactly I'd be gaining?  Is there a big weight difference?

--- End quote ---

Not only is the chassis stiffer, the suspension is head and shoulders better than a 500 suspension. the rear suspension hasn't changed dramatically since 89, different valving and maybe a larger diameter shaft, the 250's have gone through at least a 6-8 updates. The bike is much narrower than the K5 just an all around better handling bike. I used the K5 radiators and made the brackets for the lower mounts, they work perfectly. I've had a number of K5's, a Rocket Science racing framed K5, 2 K5's in 250 chassis and 1 in a KX250f chassis, and I can honestly say the newer chassis rule, the 250f is the best but way to much work.

As for Deviousfred, if your the guy from the other kawasaki forum, you can obviously make anything fit into a frame, my comment was that it wasn't easy and if you were going to do it find a 250 frame and save yourself alot of headaches. You could do a 250/500 mod in a weekend.

SPD FRK:
I have a '93 KX125 and a '91 KX500. I was told (possibly incorrectly) that this series of chassis is the same between the 125/250 and very similar to the '98 model year.
I have not really torn (or looked very hard) at the two bikes side by side yet... I have some top notch resources for fabrication so that is not a deterant (short of spending $3k and 100 manhours).

What a KICKASS SITE BTW!!!

Woodsplitter:
Hello,
   I've been a member for about a year and been lurking mostly,and I've learned alot. I've got a 5hun motor and a possible good deal on a 03 kx250 chassis. I am curious Don46 why you mentioned to stay away from that particular year? If not the 03 then what would be the best kx250(steel frame) candidate for the transplant.Any and all suggestions appreciated. 

BDI:
Im not sure why don would say not to use a 03 chassis. When I built my bike I used a 02 chassis there are a few things the are a pain in the but one of them is the head stay, 02 chassis the head stay Is on the front this Is a pain to work around O3 the head stay is on the back just like the 500 all you should have to do is cut it off  and shorten It up and weld It back. I would assume every thing else to be the same as far as mods go but I am very anal so I did a lot of stuff that other people don't bother with so doing things my way gets involved.

don46:
The reason I would stay away from an 03, its kind of a 1 shot wonder, 99-02 are pretty much the same, 04-07 pretty much the same. If you were to get the whole bike the 03 would be fine, but if your going to try to get the parts don't use the 03 as there aren't as many, primarily swingarm and linkage are the biggest difference. I've pieced them togather from parts off Ebay and rarely do find 03 parts. I had an 03, it was a great bike, just all alone in design.

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