2003 KX 250 SF Conversion

[umberto]

Thank you reklessj!  I plan to attack the physical therapy and get as close to 3 months as possible.  I can't have the surgery until late July, and I really need to be ready for Christmas season at the store. 

[umberto]

Today is one of those days that is torture if you can't ride.  High 80s, low 90s, but pretty decent breezes.  I repaired all the crash damage to Goliath (broken clutch perch, front end was a bit tweaked), and updated the look a little bit with the green side plates.  I also added the Pro Circuit fork decals I got from Australia.  

Ugh, I wish I could ride this beast...

[umberto]

The KYB kit forks that are on Goliath have always been a point of concern with me.  The 2003 triple clamps bottom out when tightening on the forks, and I don't think they are getting a good bite.  I tried contacting Emig racing to see if they still had the triple clamps that Pro Circuit used back in the day; they didn't carry them, and they wanted $800 to do a custom set.  Undaunted, I busted out the old trusty calipers and Sandblaster's awesome interchange list and was able to determine that the 2001 triples are exactly the size I need for the forks (the Pro Circuit forks are 46 mm, but larger than the earlier 98 models forks they were meant to replace).  I got a set of the clamps, and bingo they fit great on the forks.  The only issue I have is that the steering stem on the 2001 is shorter than the 2003.  It looks like the stem from the 2003 is the same size in the clamps, so I should be able to press it into the 2001 lower triple.  I have never had to press out the triple clamp stem, so I wanted to see if anyone had any tips or tricks.  I watched a video on Rocky Mountain and it seems pretty straightforward, but I figure it's cheaper to check with you guys first.  Anything I should watch out for?  My father has a 30 ton shop press, is that sufficient to accomplish the job?

Thank you!

[umberto]

I got the steering stem pressed out of the 2001 triple clamps and pressed back the 2003 stem.  Very easy process with the right tools and a press.  I used this video as a reference:

https://www.youtube.com/watch?v=2R92wxhc4_E

I bought that Park Tool they recommended and it worked like a champ.  Once I got the bearing installed, I installed the clamps on the bike.  The new clamps get a very good grip on the forks, which is comforting because I'm pretty certain that the forks turned in the clamps when I hit the concrete chunk causing the big wreck.



I have an issue with the non brake fork lug threads being stripped, and I still need to fit the front number plate, but another ride report should be coming soon.

[umberto]

I am happy to report I finally got the carb tuned correctly. You can roll the throttle on from any gear and rpm, and it just pulls. I ended up coming in two more full turns on the power jet. This motor is stout, but really manageable if you treat it with respect.

With the triple clamps sorted, the kit suspension is perfect for the bike and I am really starting to love riding this bike. I'm at my parents this weekend, so I'll try to get a ride video together tomorrow.

[FL_Sharpshooter]

I am happy to report I finally got the carb tuned correctly. You can roll the throttle on from any gear and rpm, and it just pulls. I ended up coming in two more full turns on the power jet. This motor is stout, but really manageable if you treat it with respect.

With the triple clamps sorted, the kit suspension is perfect for the bike and I am really starting to love riding this bike. I'm at my parents this weekend, so I'll try to get a ride video together tomorrow.

Glad to see you got your carb sorted. How crisp is it in comparison to the OEM carb? Did you have to fiddle with the main needle any? Let's see some new videos of it!  

[umberto]

It is a lot more crisp than the stock carb. I had to switch from the 5x needle to the 3x needle, and turn the power jet in four turns or so to get it right. Once I got it dialed, it made a huge difference over the stock carb. I think you will be pleased with yours.

I will definitely get some video tomorrow. I'm really pleased with how it's turned out.

[umberto]

Goliath in action:

https://youtu.be/txLSPxKpuzk

[FL_Sharpshooter]

It is a lot more crisp than the stock carb. I had to switch from the 5x needle to the 3x needle, and turn the power jet in four turns or so to get it right. Once I got it dialed, it made a huge difference over the stock carb. I think you will be pleased with yours.

I will definitely get some video tomorrow. I'm really pleased with how it's turned out.

Awesome. Just curious - what state do you live in? I haven't tested the Lectron yet, but hopefully the 5-2XL needle will work for my application. Hopefully I get good results like you did!

Goliath in action:

https://youtu.be/txLSPxKpuzk

Bike looks and sounds awesome!

[umberto]

Thank you for the compliments on the bike. It's turned out better than I could have hoped. I will need to address the fuel capacity soon, which is something you might want to consider as well.  It goes through a tank in a heartbeat.

I live in Oklahoma City at 1,100 feet above sea level. Where the video was made is in southeastern Oklahoma which ranges from 450 to 2,500 above sea level if we get into the mountains. i hope these settings will work back in OKC, but I may have to make a tiny adjustment to compensate for the extra 700 feet. I'm pretty sure your 5x will work.  My motor is bored, and everything I've read says bigger bore motors run a little leaner than stock bores. I could be off on that, but my motor always seemed to like leaner carbs.

[umberto]

I finally got around to getting my graphics ordered from Decal Works.  They are great to work with, especially if you have a lot of different parts like I do.  I always deal with Sean, he's the man.  Anyway, here is what I came up with:



Got some small custom touches included:



Front View:



I got a new head gasket in hand so I can send my head off to Larry for a compression release.  While I have it apart, I am going to powder coat the frame and swingarm flat black.  That is if I can stop riding it for a couple of weeks.  Now that the carb is dialed in, it's a bit like having a drug addiction.  

[umberto]

I went riding yesterday, and the carb did not seem to notice the additional 700 feet of elevation.  It's good to know that the Lectron is not terribly sensitive to changes in altitude. 

The only issue I had yesterday was that Goliath makes my 250 a little boring to ride.   

[umberto]

I've always been concerned about the motor in Goliath being a one year wonder.  I've been wanting to put some stuff away just in case, so I scored a set of extra cases from Sandblaster.  They were treated to some custom mods, and of course a vapor blasting.  Only issue I have is they make the ones on the bike look a little tattered.   I'm so glad I don't live closer to his shop, or I'd have to sell a kidney or something to pay my vapor blasting bill.  

[dave916]

So you decided to get 89on cases

[umberto]

Those came from an 88 that Sandblaster was parting out.  I may try to snatch up the cylinder head as well.