Author Topic: Installing 2017 KX 250F plastic on my 2004 KX 250, 2003 250, 2005 125  (Read 95052 times)

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Offline umberto

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We started this conversation in another thread, but I wanted to document the process without hijacking another person's thread too much.  

Dirt Bike recently had a feature in its Two Stroke Tuesday e-mail series about Pro Circuit Racing installing 2017 plastic on a 2005 KX 125.  Needless to say, it looks really nice.  One added benefit is that the tank and seat allow for a much flatter transition.



Pro Circuit is going to be producing a kit to recreate this conversion in the fall, but I figured I would try to recreate the results without waiting for their kit.  The first step was trying to figure out which bike's stuff they used.  The 250F and 450F have different mounting tabs for their shrouds, so all we need to do is figure out from the pictures posted by Dirt Bike how the shrouds mount.  If you look closely, there are two outward facing bolts on the tank, which makes the plastic and tank 250F.



The two models share a subframe, so that is not an issue.  We just need to figure out how they mounted it.  Judging the distances from the exhaust and plastic mounting hole to the subframe mount on the right side, it looks like they just bolted that side up.



The left side is a little bit more of a challenge.  It requires a bracket to get to the mounting hole.  It should be pretty easy to fabricate, seeing as how the other side and the top will hold the subframe in place while you measure for the bracket.



The PC airbox uses the stock 125 airboot, so I imagine they just made a plate out of aluminum and mounted the 125 internals inside the 250F box.  I did something similar on my 500 conversion, and it's pretty simple.  You can buy just the outer box and front cover of the airbox from Kawasaki, so I'll be doing that.  I'll cover the airbox conversion later.

The shrouds mount in three places with bolts, and will require at least a bracket off the radiator brace.  The only thing I am not sure about is how they attach to the actual radiator.  It looks like they are held in place by a plastic post.  Thankfully, there are aftermarket louvers that you can buy that are relatively inexpensive. I'm thinking I may need to do some fabrication to attach the post to the two stroke louvers.



Kawasaki wants a ton for their seat assembly, so an aftermarket seat is in order.  Unfortunately, SDG doesn't make a seat yet.  Acerbis does make one of their X-Seats for it in black or green.  There is also the eBay route, but there is only one listed and the seller wants more than the X-Seat.

I will be using the 2015 front number plate and fender that are already on the bike.  The 2017 fender is not that different, and the 2017 front number plate is a bit flimsy looking.  No sense changing a good look just to get everything up to 2017 standards.

That is what I have figured out so far.  I will be looking for the parts used on eBay to save money, but it may be a little while to find them.  I'll keep you posted.
« Last Edit: June 28, 2019, 03:12:19 AM by umberto »
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #1 on: May 29, 2017, 03:02:23 AM »
Well, looks like I lucked out.  There was a guy selling the subframe and the tank on eBay for big savings.  Score!  They should be here later this week or early next week. 
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline FL_Sharpshooter

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #2 on: May 29, 2017, 08:49:52 AM »
Sounds like an interesting project. I'll be watching this one. I was thinking about converting over to the 2017 plastics also on my 500, I do know that there will be quite a bit of fabrication.

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #3 on: May 29, 2017, 09:46:29 AM »
I thought it might a fun project for the summer.  It gets so hot in July and August here that you can't do much riding.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline FL_Sharpshooter

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #4 on: May 30, 2017, 12:27:53 AM »
I thought it might a fun project for the summer.  It gets so hot in July and August here that you can't do much riding.
I hear ya there, it gets so ungodly humid here in the Florida summer, especially with it now being in the rainy season. I usually just ride in the morning for a few hours and call it a day, the sun just drains the energy right out of ya!

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #5 on: May 30, 2017, 05:19:25 AM »
The subframe and tank shipped today, and eBay is estimating a Thursday delivery.  I did see one issue with the mounting that I will need to address.  The 2017 subframe mounts from two sides with individual bolts that thread in to the frame, while the 2004 used one bolt that screwed into the other side of the subframe. I am trying to make the conversion bolt on, so that I can switch back to the 2004 plastic if I don't like it.  I have an idea on how to make it work, but I will need to get everything in my hands first.  Here is what I am talking about with the mounting:


« Last Edit: January 06, 2018, 02:31:13 AM by umberto »
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline KXDINO

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #6 on: May 30, 2017, 07:11:30 AM »
i heard the 19 kx450 is a whole new bike so i gather it will have fresh plastics on it , you might want to put the 19 stuff on your k5 umberto to bring it up to date . :-)

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #7 on: May 30, 2017, 07:26:35 AM »
I can do it.  I still have the 500, a 250, and a 125, so I should be covered for a few updates.   :-D
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #8 on: May 30, 2017, 09:37:05 AM »
I got my plastic, seat, and air box ordered today. The air box is back ordered, but the plastic and seat should be here by Friday. That should at least let me set up the subframe and plastics.  eBay updated to show the subframe and tank getting here on Thursday.  Saturday is shaping up to be a fun day in the shop!
« Last Edit: May 30, 2017, 11:32:18 AM by umberto »
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #9 on: June 02, 2017, 09:56:50 AM »
OK, so I got most of the parts in (the airbox halves are still on backorder) and was able to start the mock-up.  I started with my 2004 KX 250.  First thing I did was to remove the plastic, gas tank, subframe, and exhaust.  



It took a little sanding on the left side, but I was able to fasten the subframe and the top and left:



The gas tank slips into the frame rails, as long as you remove the two rubbers on the sides.  The back ones appear to be on the frame in the PC pictures, so I left them.  More on the tank in a second:



So at this point I am feeling pretty good about the whole process.  That was until I tried to mount the long piece of plastic on the left side.  The radiator scoops were too far back to catch the side number plates.  It was about an inch too far back.  I switched gears a little bit and mocked up the right side of the subframe so I could at least test the fit of the seat and see if it was in spec.  I used a little bit of aluminum strap; the final piece will be 1/4" aluminum and will require a bit of welding.  I didn't have any 1/4", so I decided to just mock up so I could continue on with the fitment.



Mounting the seat confirmed that it was at least an inch too short.  I think it may have something to do with the tank being too high in the back, so I may need to do some heating.  I tried to remove the bolt at the front of the subframe and let it rotate back, and I was able to get everything to fit.





The tank should be able to come down about an inch before it hits the subframe, so I think I may be able to heat my problems away.  As you can see in the second picture, the tank on my bike rides out from the frame more than the PC bike.

Tank clearance:


Frame Clearance:


Anyway, that's day one.  I think this is doable, it's just going to take some work.  I'll keep you guys posted.

« Last Edit: January 06, 2018, 02:31:41 AM by umberto »
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #10 on: June 03, 2017, 09:58:42 AM »
Before I heat the tank, I figured I would try spacing the subframe up to see if that helped.  I was able to get everything to line up using about a 2 1/2" spacer on right side and I added about that much to the spacer on the left side.  I used vise grips to hold it in place:



It fit really well, but only Rik Smits (former 7'4" Indiana Pacers center and dirt bike lover) could ride it.  

Here's Rik:



Here's the bike I built for him:



I figured it didn't cost me anything to try and it eliminated that as a possibility (no offense Rik Smits).  I am going to get out the heat gun tomorrow and try to match the gas tank gap on the PC bike.  I think that is the way home from here.  I love the looks, except for that dang X Seat, which I forgot how much I hate, so I think the work will be worth it.  I'll keep you posted on tomorrow's progress.
« Last Edit: January 06, 2018, 02:32:37 AM by umberto »
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline mikectanker

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #11 on: June 03, 2017, 02:07:59 PM »
That's  cool. I remember Smits.  Still have a few of his trading cards in a bin from when i was a kid.

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #12 on: June 04, 2017, 04:48:38 AM »
A little more measuring revealed that even lowering the tank with the heat gun won't make the plastic line up.  I think Pro Circuit spaced the subframe back at the top so the plastics will line up.  I'm actually going to try to call them tomorrow and see if they will reveal some secrets of the swap.  If not, I may just wait until their kit comes out since I have all the stuff already.  No sense tearing stuff up just to try to reinvent the wheel.
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline DP3601

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #13 on: June 05, 2017, 12:34:20 AM »
A little more measuring revealed that even lowering the tank with the heat gun won't make the plastic line up.  I think Pro Circuit spaced the subframe back at the top so the plastics will line up.  I'm actually going to try to call them tomorrow and see if they will reveal some secrets of the swap.  If not, I may just wait until their kit comes out since I have all the stuff already.  No sense tearing stuff up just to try to reinvent the wheel.

Wow you got busy with that one, I was sure hoping it would work out for you.   I am curious if they will give you any information!

Offline umberto

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Re: Installing 2017 KX 250F plastic on my 2004 KX 250
« Reply #14 on: June 05, 2017, 12:40:28 AM »
I'm hoping that I can play the admin at KX Riders card. Maybe he'll give me a pre-production kit so I can do a write up for the site. If you don't ask, you don't get.  :-D
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144