2003 KX 250 SF Conversion

[dave916]

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

At a glance they look like 89on , not the best pictures though
How many kipps holes on base gasket surface

The 88 stuff will fit on the 89 cases ok

[sandblaster]

I wished they were 89 and on... I would have sold them for WAY more 

[dave916]

I wished they were 89 and on... I would have sold them for WAY more  

The left one in picture {clutch side} is defiantly 89on
Not 100% sure about flywheel side unless i see the inner or top side

Maybe someone fitted a set of 89 cases to the 88motor  sometime

[umberto]

I'll try to get some more pictures tomorrow for you guys to look at.

[umberto]

Here are some pictures of the cases from a little closer with better lighting.

[umberto]

I guess I should ask the obvious question: If the clutch side is 89 and up, will it still work with the ignition side if it's an 88?

[dave916]

I guess I should ask the obvious question: If the clutch side is 89 and up, will it still work with the ignition side if it's an 88?

They are a set of 89on cases / they look pretty good

No problem fitting ur 88 stuff to them  , only extra bits u need are a case pin dowel  /gearbox bearing retainair {about $8 total}

Main differance on cases are extra hole for  kips{88 top end still fits }
 Bigger engine mount hole 10mm /8mm on 88
Less case volume on 89on {which might not ideally suit you big bore}  but at least u have option of fitting a later topend  

89 case are way to go

[umberto]

Do I just need these two items?

[dave916]

That them  

IF you had a early motor {86} the 89 cases would not work

[umberto]

I've been trying to increase Goliath's fuel capacity for a long time now, without much luck. The IMS and Clarke tanks for the 2004 didn't work, they hit the head where the petcock came down.  The IMS tank for the 2007 had the same problem. ZZ3GMC suggested the Clarke 2005 to 2007 tank, so I ordered one from justgastanks.com in black. It finally came in Friday and I had a chance to work on it today. It did not have the deep petcock area so it was much closer to fitting than any of the other tanks, but it did need some adjustment. I was having the most problems in the head stay area, which required both some grinding on the head stay and heat gun work. In order to spread out the pressure and not poke a hole, I made a cover for the area out of 2" PVC that I cut lengthwise so it would slip over the area.   I would heat the area on the tank, and then put the tank on bike so I could apply pressure and hold it while it cooled.  I slowly added some Gorilla Tape to make the PVC thicker, and re-heated the area. It was slow going, and the PVC piece had to be pretty thick with tape when I was done, but it fits really well.

Here is the PVC piece:



Here is the tank mounted:



All buttoned up and ready to go:

[zz3gmc]

Did you use the standard mounting hole by the steering head? My tank is spaced up slightly. I made a short extension bracket and bolted it to the existing mounting hole which let me mount the tank flush with the frame and forward. My lower radiator mount is moved forward about an 1/8" to provide clearance by the head for the bottom of the radiator tanks. If left in the stock position the tanks hit the head. Ill be putting the bike back together (after a loooong 2 year rebuild) so Ill try to take pics.

[sandblaster]

Wow!
Very nice work.
Somehow I missed the questions on the cases..
Sorry about that...

[umberto]

Did you use the standard mounting hole by the steering head? My tank is spaced up slightly. I made a short extension bracket and bolted it to the existing mounting hole which let me mount the tank flush with the frame and forward. My lower radiator mount is moved forward about an 1/8" to provide clearance by the head for the bottom of the radiator tanks. If left in the stock position the tanks hit the head. Ill be putting the bike back together (after a loooong 2 year rebuild) so Ill try to take pics.

I did have to redo my top mount with a small bracket, but it fits down pretty close to flush in the back. It clears the head and everything else really well now. Thank you for suggesting the Clarke tank, it saved me a lot of work and expense with plastic welding.

[umberto]

Wow!
Very nice work.
Somehow I missed the questions on the cases..
Sorry about that...

Thank you sandblaster!  No worries on missing the question, I know you've been busy.

[umberto]

I got the oversized tank to fit, but there were a couple of areas that concerned me and I kept remembering that zz3gmc told me that he had to center his head stay mount in order for the tank to fit.  I decided to tear Goliath back down and center the head stay to gain more clearance by the petcock area.  It was about a four hour project, but it was really worth it as I gained some clearance behind the petcock.  In welding class I had previously cut the stock head stay back, shortened it, and put a piece of plate in to connect the two halves.  I did not move it from the stock offset location, which is about 1 1/2 inches off the shock mount.  I moved it over today to be in line with the shock mount.  Much further the other way and it would hit the other side of the tank.



My welding is a little crude, but I tend to over stick the items and then grind them back a couple of times until only looks like a fifth grader (not a first grader) welded it.    If you are building a conversion on this chassis, I would highly recommend doing this from the get go.  It will save you a ton of work down the road.