Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
K5 in a 250 frame
jfabmotorsports.com:
--- Quote from: The Flyin Hawaiian on December 01, 2009, 04:23:31 PM --- My fiance actualy figured this out when she was installing a Clarke tank on her 07 KX250. Before she put it on her bike, she placed it on my 250/500 project.
--- End quote ---
Never mind the project! You better hang onto her. Most of my friends women can't even tell you what brand bike they ride even if they are looking straight at it.
bob larry:
2nd that! How old is the sister?
PowerFiend:
--- Quote from: The Flyin Hawaiian on December 01, 2009, 04:23:31 PM ---Ive been off for a while, had to buy a new computer! Anyhow, Im doing a 500/250 conversion using a 04 KX250 (2t) chassis. Im almost done with most of the tough stuff, its was much easier than I had thought. You can solve the fuel issue by using a 05-07 KX250 2 stroke tank. It fits with very little modification, you will have to heat the tank above the plug and fab up a new mount bracket of some sort where the Clarke tank bolts in front, it is slightly off. In 05, the 250 got a new frame that is narrower so a 03/04 tank wont fit a 05-07 frame. The 250 also got a new motor where the cylinder sits in more of a straight up position. Because of this, there is now clearance for the 500 cylinder. My fiance actualy figured this out when she was installing a Clarke tank on her 07 KX250. Before she put it on her bike, she placed it on my 250/500 project. It looks like it was made for it. If the 05-07 IMS 250 tank still uses the little side "L" brackets, you may not need to go with the Clarke. I cant confirm this though because I dont have a IMS to test fit. As far as the radiators go, im using the 250 rads. I will use the top, stock position frame mount and angle the bottom of the rads forward to clear the cylinder. The cross over is a tight fit. Im going to grind out the welded seam and have it flush welded. This should provide enough clearance. Im also going to space the rads out from the frame slightly. This should make getting to the lower crossover tube hose clamps easier. One more thing concerning the large tank, the rear frame headstay almost touches the tank where the petcock is. I dont think it will be easy to heat this area ot the tank up for claearance. So, im going to cut the frame mount out and move it to the right and line it up with the headstay. This way, spacers or offset brackets wont be needed. Hope this helps you guys out some.
--- End quote ---
Most Excellent... :evil:
How much of a gap is left between the 05+ clarke and the 03-04 frame? Perhaps fill it with hot water and do the tank expansion trick??
I would go with the clarke, the IMS tanks are a nightmare to perform slight molding with. The are like trying to remold a candle with a blowtorch.
PowerFiend:
--- Quote from: BDI on December 01, 2009, 11:12:02 AM ---If I was going to use a 125 frame I would get a donor 500 frame and cut the whole cradle out of the 500 and graft it to the 125 frame.
--- End quote ---
This would be way more work, the 500 frame rails flare out with the main tube to the pegs, the 125/250 flare into the linkage. The 125/250 frames also have the rails extend all the way up to the square downtube, where the 500 has that clam shell around the round downtube. ... at least on the 98 + 125/250 frames, I have not looked at anything older.
PowerFiend:
--- Quote from: The Flyin Hawaiian on December 01, 2009, 04:23:31 PM ---Ive been off for a while, had to buy a new computer! Anyhow, Im doing a 500/250 conversion using a 04 KX250 (2t) chassis. Im almost done with most of the tough stuff, its was much easier than I had thought. You can solve the fuel issue by using a 05-07 KX250 2 stroke tank. It fits with very little modification, you will have to heat the tank above the plug and fab up a new mount bracket of some sort where the Clarke tank bolts in front, it is slightly off. In 05, the 250 got a new frame that is narrower so a 03/04 tank wont fit a 05-07 frame. The 250 also got a new motor where the cylinder sits in more of a straight up position. Because of this, there is now clearance for the 500 cylinder. My fiance actualy figured this out when she was installing a Clarke tank on her 07 KX250. Before she put it on her bike, she placed it on my 250/500 project. It looks like it was made for it. If the 05-07 IMS 250 tank still uses the little side "L" brackets, you may not need to go with the Clarke. I cant confirm this though because I dont have a IMS to test fit. As far as the radiators go, im using the 250 rads. I will use the top, stock position frame mount and angle the bottom of the rads forward to clear the cylinder. The cross over is a tight fit. Im going to grind out the welded seam and have it flush welded. This should provide enough clearance. Im also going to space the rads out from the frame slightly. This should make getting to the lower crossover tube hose clamps easier. One more thing concerning the large tank, the rear frame headstay almost touches the tank where the petcock is. I dont think it will be easy to heat this area ot the tank up for claearance. So, im going to cut the frame mount out and move it to the right and line it up with the headstay. This way, spacers or offset brackets wont be needed. Hope this helps you guys out some.
--- End quote ---
P.S. Any chance of some pics? :-D
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