Maintenance & Technical > KX500 Steel Frame Conversion (SFC)

my 2001 KX 250/500 conversion

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KXer:
Well the time finally came to get off my butt and get the K5 engine (that has been sitting in my garage for 6 months) in my 01 KX250.

Well, got the project started, no big headaches just yet.  Got the 500 sitting in the frame with the bottom engine mount bolted.  I have the front engine mounts ground off as well as the rear head stay on the K5.  I was also able to mount my kx250 radiators using the stock mounting locations without any modifications needed.  Unfortunately that is where my project is at a pause since I am waiting on a new swingarm and my shorty plugs to arrive in the mail.

Left todo:
-Shorten the swingarm mounts and spacers once I get the new swingarm.
-Fab new front engine mounts.
-Fab a new head stay.
-Figure out my pipe situation.  (I am thinking though that I will just bite the bullet and buy the one from AJ that he uses on the KX500AFX - I think it will fit)
-Helicoil (sp?) the oil plug as the previous owner of the k5 jb welded the plug in, so I am assuming it is stripped.
-Should also get a new clutch/case cover as this one has been "repaired" - this would just be a peace of mind deal though.
-Reassemble.
-Fire her up.

Here is the frame:


and the power plant:

sintax:
sounds good man. Its a fun project. Let me know if you have any questions about anything. I'm having a pipe made for mine right now. I MIGHT have it back next year if i'm lucky. I can already tell this guy is a total slacker.

As for AJ's pipe, from what I read it wont be a bolt up deal, you'll need to modify it "some" but it is the closest premade pipe for the job.

KXer:
Ya thats what I read in your thread.  It still seems easier than getting a custom one done up, but we'll see.

Any chance you have some pictures of the head stay you made.  I understand how you did it, but pics make it easier.  Oh and I decided to do all the work myself too (not that shop that you and I talked about via PM's), its been a WAY easier project than I anticipated.

sintax:
I'll take some pics of the headstay when i get the bike back.

KXer:
FedEX brought me my new swingarm in the mail today and it came with good needle bearrings and spacers.  Now I just need to find a machine shop to cut down the spacers, the swingarm I can do myself.

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