2003 KX 250 SF Conversion

[umberto]

No suspense.  . I went with silver and flat black on the frame guards.

[umberto]

The only small issue I have with the plastic conversion kit is that it leaves the airbox a little more open than I would like.  It may not ever be a problem, but I just don't want to take chances with as much mud and sand as we ride in.  I fabricated some plates from aluminum to fill the sides of the box so that it is better covered.  I did notch it for the openings in the side plates, so the airflow should be good.  I used a rivnut to hold them in place, and painted them in semi gloss black.  They are removable if I ever want to remove the plastic conversion.  Overall I am pleased with the results, but I ordered some ABS plastic from the devil (Amazon) so I may redo them in plastic down the road.

[umberto]

Here it is after I painted it.  The scratch is covered by the side panels, so I'm not going to worry about it.  That's what I keep telling myself.   

[umberto]

Got my frame and other parts back from the powder coater yesterday. Ready to start final assembly.

[umberto]

We’re waiting on big print job at work, so it was a little slow today. I was able to sneak out and get a little work done. I got the motor in, the forks on, the wheels installed, the new IMS pegs installed, the radiators installed, and the wiring and electronics installed.  I’m pretty close to done, with just a few items to button up. One of the slow downs is the rear brake carrier.  I wanted to use a TM Designworks rear hub carrier for a 2009 and up KXF, and I thought from my experience with my AF conversion that it would bolt right up. Unfortunately the calipers are slightly different, so I have to use the KXF caliper and brake line. I bought a used one on eBay, so I’ll be waiting to finish until it arrives.

[umberto]

I made some more progress today. It’s mostly done, I just need to install the back brake and chain. I switched to an 09 rear brake caliper so I could use a TM Designworks rear brake guard and carrier. The 03 caliper hits on the swing arm due to a change in where the banjo bolt attaches. Here is a picture of where I stopped.

[ftc]

she's a beauty, let the good times roll! 

[sandblaster]

Yep... that bike looks sweet...

[umberto]

Thank you!  I'm going to have some pictures made, and then it's back to the dirt.  I've been cleaning on it for two solid weeks, so it may be hard to get it dirty at first.   

[umberto]

I got some more done today. I added the graphics, chain, case guard, and fixed a broken CDI mount. All I lack now is the brake caliper and line, airbox mud guard, and frame tape. The USPS may or may not have them close by. Their tracking is garbage.

[umberto]

I had the CDI mounted on the side of the frame because it wouldn’t mount behind the number plate without a fork hitting it when I turned. The mounting bracket cracked off, so I needed to find a better way to mount it. It really cleans up the wiring to put it behind the number plate, so I bent up a steel bracket, welded it to the stock mount (that I miraculously kept), lined it with rubber matting, and zip tied it in. I think it will be way more secure and the wiring is a lot cleaner.

One other change I made was to run the wiring forward and up the clutch cable, instead of back and up the frame rail. I think it looks a lot better, and I don’t have to put zip ties on the frame.

[umberto]

A couple more finishing touches tonight before I get some better pictures made on Friday. I added the frame tape I found on eBay, the rear mud guard, and the 2009 KX250F rear caliper. I was able to use the 2003 brake line with the KXF caliper without any trouble. Here are a couple of pictures I took.

[umberto]

I decided to get some pictures made of Goliath. I was able to get a different photographer, but at the same studio. This guy had a lot of great ideas for different angles and lighting. I’ve seen a few preliminary images, and they were really nice even before editing. I took a few pictures of the setup; I’ll post the final results when he sends them over.

[umberto]

I’m really excited about the pictures with this background. They looked great on the viewfinder of the camera.

[reklessj]

Man those pics need to get framed n put on the mantle right next to the family photo😂🤣🤣😂😂