Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
my 2001 KX 250/500 conversion
junk man:
hey kx'r we need to see where yours broke I'm thinking it cracked the down tube if so you could get a piece of 0.45 tubing and split it use about five inch piece remove your old mount and weld any cracks grind it smooth then slide half over the back side of the down tube and weld it top to bottom don't weld around the tube then use 1/8 inch flat plate make your engine plate about four inch long and weld it to your doubler we'd like to help with your problem any way we can JM note this might not be the best idea
I also used stock mount trimmed down so far its good also BDI's head stay is well built and definitely not a week link 8-)
The Flyin Hawaiian:
I was gonna use thicker mounts on my bike but after reading BDIs comment Ill stick to the trimmed down stock mounts.
KXer:
The engine mount crack is not on the frame or the weld, the steel gusset snapped. - will get pics tuesday ~ hopefully
The head stay cracked after the weld - again, I'll put pics up Tuesday.
Thanks for the input.
BDI:
I like the idea of grafting the KX500 cradle into the 250 frame. Having never tried this I have no idea if it would work or not. The best thing to do is use the 250 mounts and do it just like the factory did in my opinion. I think this is one of those cases where over kill is your enemy. Also if you notice the factory starts there mig welds before the the mount and ends it after the mount. This is done so there is no cold weld to start a crack.
KXer:
UPDATE:
Took the bike from so cal to Colorado. pulled it apart, the headstay plate (that gets used to grab the 5 head studs) snapped in half. This was because the nut came loose that holds the heads stay to the frame. . . my bad. Gusset on the front engine mount was cracked, engine mount was not. . . yet. Fixed both.
Rejetted for the elevation and the bike fired up. let it warm up and then it died. swapped the plug to find it was fouled. Still would not start. Long story short, somehow (I think) the stator wires got yanked causing VERY low spark. It would bump start (after 2 trips around my brothers 4 acres) but it was running horribly. Because Im stubborn, I kept at it and smoked the rings. I now have no compression, Im just HOPING that I didn't blow any seals in the bottom end.
Brought the bike home, didn't get to ride the IMI mx track that is 3 minutes from my brothers house. replacing rings, reeds, swapping back in socal jets and will have to look at the stator to see if whatever got pulled is repairable (But fear a new ignition is in order) - Anyone have a good running 500 ignition?
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