2003 KX 250 SF Conversion

[umberto]

Thank you motopunk!  I'm having a blast building it.

[zz3gmc]

Bike looks great! I would weld another mount to the sub frame for the silencer. Thats alot of silencer hanging back there for one mount. I have 2 mounts on my bike. Also you should beef up that lower mount for the pipe. 500s vibrate  quite a bit and that "Z" shaped bracket may fail. A upper pipe mount for a 05-07 KX250 may work there since they are pretty long. The 03 frame also has a mount for the expansion chamber by the subframe to frame junction. I would make a mount there also since the CR pipe has a mounting point there. Not nit picking just offering some suggestions to more solidly mount the pipe.

[umberto]

Thank you for the input zz3gmc!  Without your help I wouldn't have gotten this far for sure. I'll take your advice and beef up my mounting. i haven't had a k5 for 30 years, so I wasn't sure how much vibration is normal for one. 

[Foxx4Beaver]

so what color(s) are you thinking when buying plastics, backgrounds and decals/graphics?

[umberto]

I was thinking about using the 2014 KXF front fender and number plate in green, 08 KXF shrouds in green, and stock side panels and fenders in green. I think I'll leave the fork guards black. I had a really good experience at Decal Works last time, so I think I'll go back with their graphics. I really like how edgar_kx3 did the yellow backgrounds on his, so I am going to borrow that from him.

I like this graphics set, but with KX 500 where it just says KX.

[Foxx4Beaver]

that'll look sharp!.

[zz3gmc]

I like yellow and green!

[umberto]

Nice.  That dude looks like it means business.  Is that the 04?

[umberto]

I got the electronics wired in today and was rewarded with a big fat spark!  Always one of my favorite moments for sure.  I am really just down to modifying the tank, and the airbox and I will be able to ride it.  I did run into a bit of a snag today.  The clutch cable I got with the bike and the one from the 250 are both too short to reach the clutch perch.  Is the K5 one much longer than the 250 ones?  I routed the cable exactly like my 04, and it was close but not anywhere near usable.

[zz3gmc]

Thats the 04 hybrid.

[zz3gmc]

I used the stock 500 clutch cable. I bent the metal tube so it will route in front of the radiator just like the 250. That eliminates the sharp bend at the top of the radiator when routing it like a 500. Seems to ease the pull somewhat. I use a Moose clutch perch/lever with 2 holes for the cable and a bearing in the pivot. The pull is as easy as a 250. Ive tried juice clutches before on a YZ426 and a CR250 with poor results. It gave them a on/off feeling with no "feel" or modulation. Plus both started leaking at the slave cylinder during a race and left me with no clutch. I went back to the cable after that.

[umberto]

I was able to get the cable in the perch, but it is too tight for serious riding.  It does have a nice light feel though.  I think I'll order a 500 cable and see if that helps.  I don't think the cable the guy gave me with the motor was for the 500.

[umberto]

Rocky Mountain does not have a clutch cable for the 88 K5.  A 90 cable should work, correct?

[zz3gmc]

Not sure, the part #s are different. If the mounting point on the case is the same I dont see why a 89-04 cable wouldnt work. Can you post a close up pic of the left side of the engine?

[motopunk]

the cable works .. i have one on my 88 motor ..  kx250 and 500 could be assembled with the same cables 88-2004 

it could also fitted to 85-87 motors, but thatīs not the point here ...