Maintenance & Technical > KX500 Steel Frame Conversion (SFC)

my 2001 KX 250/500 conversion

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KXer:

--- Quote from: gwcrim on March 27, 2009, 01:53:59 PM ---Any special tricks to getting the tank to fit?

--- End quote ---

Well, I used a heat gun, plastic tipped hammer (though any decent hammer would also work), and a large file.  I had to completely change the shape of the bottom of the tank (right where it meets the head) with the heat gun and hammer.  Once it was reshaped and fit the bike and clearance for the sparkplug I found there was still a pinhole leak. 

Found a "Plastic gas tank repair kit" at Kragen Auto parts, (which is basically a fiberglass kit, with cheese cloth, resin and hardener).  so i fiberglass the bottom back in, then sanded down the area and also used a tube of superglue around the edges.  Tested it with water - no leaks, then tested it with premixed fuel and is holding up great.

I will try to remember to snap some photos of the bottom of the desert tank tomorrow.

KXer:
**UPDATE** SHE RUNS!!  I can't say thank you enough for Stewart and the work he put in to my cylinder.  I highly recommend him for any K5 engine work!

I will have pics in the next few days, but here is a brief list of what I did while she was down:
New cylinder plating with window mod piston, and cleaned power valve.
Also picked up a Vforce reed block from Stewart
Head stay from Jerry )Jfab) which worked out great for me as well with a slight modification
New carb from Sudco (running a 172 main, in the 2nd position
Air box vents (3) on each side
FINALLY finished desert tank.  IT IS A PITA, to get this right, and in the long run ended up having to fiberglass and epoxy the bottom any way.
Gusseted and plated frame
Black powder coated fram, subframe, triple clamps, and swing arm.

I am heading to Glamis this weekend.  Broke in the piston earlier today.

KXer:
Some pics:

Right side


Left side


Air box vents


Gusseted engine mounts


Front

PowerFiend:
Looks real good.

KXer:
My build got moved into the right section.

Only update is that the desert tank is finally mounted.  PITA, I'd say more trouble then it was worth, but I have almost a whole extra gallon fuel capacity now.  Last sand trip of the season coming up in a few weeks, I'll try to get some new pics up.

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