Maintenance & Technical > KX500 Steel Frame Conversion (SFC)

Can I join the club?

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don46:

--- Quote from: demographic on November 21, 2008, 10:24:01 AM ---Didn't you used to have a Rocket Science Racing perimeter framed KX500 a while ago gwcrim?

--- End quote ---

I had a Rocket Science frame, never really liked it, the bike sat too tall, it was probably another 3" taller than a stocker and as for handling it was just a 500 with different plastic. The true hybrids handle much bettter and even sit better and the rocket science kit wa about 3k, so no real bargin there

gwcrim:

--- Quote from: love2ride450 on January 19, 2009, 07:50:32 AM ---Hey guys, just joined the forum today! I heard good things about this site on thumpertalk, and I needed some info about a K5 project, so here I am.

I was curious if you wouldn't mind letting me know how much AJ charged for the pipe? I have a 2003 KX250 that is begging for my 86 K5 engine, and as far as I can tell, the pipe is going to be the hardest thing to get right.
Thanks,
Josh

--- End quote ---

The pipe was a about $400 and that was with the quieter, more expensive Q silencer.

We're stretching things by using that pipe on a different chassis but the right engine.  An 86 engine may be quite different.  Could be more trouble.  Lots of cutting and welding.

gwcrim:
I was up until who knows when pondering the pipe.  I took the shock off and the pipe actually fits pretty well w/out it.  Now to get rid of that pesky reservoir.  I'll see what I can find in a shock w/a remote.  I don't want to cut up a perfectly good pipe and the rear shock seems to be leaking a bit of oil.

gwcrim:
I got the Service Kawasaki pipe stuffed in and it will fit without denting or cutting it.  Unfortunately, the reservoir on the shock hits the pipe.




This is the shock on the bike.  I've never seen one with the schrader valve that hung down below the reservoir body.  This takes up 5/8" where there's not any clearance anyway.  Even with a recessed schrader valve there will be interference.  I believe I can probably notch the body of the reservoir.  Anyone know anything about this weird schrader I have?



To mount the silencer, I'll weld a nut under the subframe for the forward mount and fab a little hangar for the rear.  The fender will need a tiny amount of trimming.



Other than mounting points for the tabs on the pipe to the main frame, that's all it'll take to fit it.  (I hope.)  Fabbing a coolant line to run from the pump to the jug may be challenging.  I have a few ideas but a Service Kawasaki hose set sure would work too.

doordie:
Bent it were stinger (bleedingpipe) begins downwards, and bend up mufflerpipe with a sharper angle were stock bend is.
This rerouting will make muffler to fit in higher excisting hole in subframe.

Just my 2 cents! :-D

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