2011 kx250f conversion w/ 1988 kx500 (Newbie)

[motopunk]

 real nice work... 
the weld seams look like a dream ... 

[LundMx]

Thanks @Motopunk! The guy who is welding it used to work for a racing manifold company doing all the intake manifold welding.. Guy is super tallented!

[brooksie]

Beautiful welding!

Yes, the radiators are a bit of a pain. Many people have used many combinations. The right side one off the 250 will work fine but the hose connectors will need rotating. It's th left that is the problem.
I bought a new, standard set of KX500 radiators, cut all the brackets off, and started from scratch. This way, I know that I have the right amount of cooling fluid etc. And the left one is not too long. I've also used the standard plumbing as well. I have a 2013 Gasgas 300 enduro ( it's very quick!), and it's exactly the same. ie The rads are plumbed in series. No point in over complicating things...

Looks like a 450 frame you're using?

[LundMx]

Brooksie, i found that out today, the kx500 rads look like i can make them work then just make another mount to the radiator shrouds.. This is a 2011 kx250f frame not 450f.. Fits good!

[brooksie]

Yeah, you'll work it. I've used the standard 250 screens with brackets welded on to the rad so the shrouds bolt through the rad into the screen just like stock. You'll have to shorten the left one a little, but it all works nicely.

[LundMx]

More big things today.. I mounted the fresh new Factory connection suspension, i got the forks from an 09 kx250f and same with the rear shock





And i finally started assembly on the motor and got it installed





Spark plug clearance is not going to be an issue



And i got the pipe welded together and fitted!

[sandblaster]

Looking really good.
If you didn't modify the tank then the 2011 tanks must sit higher in the frame then the 2007.

[LundMx]

I got the tank from a 2009 kx250f, last year of the carburator... Looks like it will work perfect

[jBernard]

09 kx450 used KYB forks.
those look just like the showas off my 250f

[motopunk]

I got the tank from a 2009 kx250f, last year of the carburator... Looks like it will work perfect

you could also use a shorter sparkplug for some clearance under the tank ...i use the ngk br8ecm ...  they´re exlusively made by ngk for the ktm sx 360 and sx 380.

... good job, will be a nice bike... 

[LundMx]

09 kx450 used KYB forks.
those look just like the showas off my 250f

i would think they would be the same

I got the tank from a 2009 kx250f, last year of the carburator... Looks like it will work perfect

good to know! i might pick some of those up! thanks for the info!
you could also use a shorter sparkplug for some clearance under the tank ...i use the ngk br8ecm ...  they´re exlusively made by ngk for the ktm sx 360 and sx 380.

... good job, will be a nice bike... 

[don46]

09 kx450 used KYB forks.
those look just like the showas off my 250f

i would think they would be the same

[/quote]
They are different, I think you said you got a set of triples from a 450, if so they would have to be 450 forks, the Showa 250 forks are smaller at the triple clamp area. The shock does look more like a Showa than a kyb but a picture is hard to tell.

[motopunk]

yes the br8ecm plugs are 20mm shorter as br8eg . my fingers love the little bit more clearance between plug and my ´93 tank. 

[LundMx]

had to go look  at my reciept, yes in fact the forks are off a 2009 kx250f and the rear shock as well... I just had thought they where off a 450f

[jBernard]

hey, look on the bright side. now they are true to the sticker 
those are great forks though. thats the reason i went with the 09+, coated fork legs.