2017 KX250F - 2004 KX250

[umberto]

I bought some stuff last year while I was waiting for the frame to be done.  Now it's like Christmas as I open the parts closet and remember what I have.   

I found these Fasst anti-vibration pegs that were on sale.  It's so nice to have a modern frame.  People actually make stuff for them. I kept the pegs that came on the bike, and will be trying to modify them for Goliath.  Hopefully I can make them work so I can get some more Fasst pegs for Goliath.

[sandblaster]

The Yamaha pegs I found were the easiest to mod to fit the KX500...

[umberto]

The Yamaha pegs I found were the easiest to mod to fit the KX500...

Would that transfer over to the 250 as well?

[sandblaster]

Doh.... Don't know 

[umberto]

Today I got my motor completely squared in the frame and made my motor spacers.  It was really close, I just needed a few millimeters to get it right.  I used 1 1/2" aluminum rod and drilled a 43/64" hole in the center, and it worked really well.  It took a lot of fine tuning with the belt sander to get the size correct, but in the end it's a really nice fit (see picture one). 

I also added an Acerbis chain slider and chain guard in lime green, and Tusk wheel adjuster blocks for a little bling (see picture two).

[umberto]

To button up the back end, I rebuilt the rear caliper and master cylinder and swapped to the correct 2017 brake line.  I also added a brake spring delete kit (see picture one) so I don't have to mess with the brake spring hitting the clutch cover.  I did run in to one snag, as it looks like the brake pedals are different so I need to order the correct one. 

It's nice to be making some progress.  I'm really held up by not having the suspension, but I still have plenty to work on.

[umberto]

I got the rear wheel buttoned up today.  I had to bend the brake lever out to clear the clutch cover, but I got it to fit and was able to bleed the rear brake.  I added a Works Connection master cylinder guard just to be safe.
 

I got a new chain as well, and as I was installing it I realized this was the first new bike I've had since 1991.  Every bike I own has issues with the chain adjusters, but this bike is a clean slate.  I added anti-seize to the adjuster bolts so maybe I won't have to deal with a frozen bolt on this bike.  I'm keeping my fingers crossed.   

[sandblaster]

 

[umberto]

I had quite a time getting triple clamps for the forks I am using (more on that later).  Everything I could find was a huge decrease in offset, or was super expensive.  I tried Topar Racing, but they don't do clamps for newer bikes.  Finally I found a set of stock offset Ride Engineering clamps on eBay.  Unfortunately the seller made a mistake in the warehouse and sent me a set for another bike.  Finally I found a guy with a set of brand new, in the box Xtrig ROCS clamps.  I got them in today, and got them installed.  I can't wait to see them with the forks installed.

I got in touch with Brett at ICW radiators https://icwradiators.com/, and we discussed a plan of attack for the radiators.  I am going to use the two stroke radiators, with some tank and hose modifications.  I'll post more on that as I get them mocked up.  

I also talked to the guy on eBay who has the kits to put 2017 KX250F plastic on your 2003-2007, and he agreed to sell me a spacer to fit my airbox.  The airboot comes up about 3/4" short of connecting to the airbox front, and one of his spacers from the kit will be perfect.  Plus it already has the mounting holes to the stock airbox and two stroke airboot.  

That just leaves me with the kickstarter to figure out.  I'm actually feeling cautiously optimistic at this point.  

[umberto]

I got another hurdle out of the way today.  I was able to fit the airbox spacer and get the filter cage mounted.  Having this spacer was perfect, but it did require some re-engineering as it was designed to mount from the other way.  It's a well made piece though, and really saved my bacon.  I think I am going to paint it black so it doesn't stand out so much.

I'm still working on my radiators.  I got the left side radiator mounted, and it will only require a bit of work on the tank.  The right side is too long to fit in the KXF mounting location, so the radiator guy is working on a solution.  He seems very knowledgeable and is really helpful.

[umberto]

I finally got my radiators figured out.  I used the two stroke radiators, but I had to raise them one inch to get them to fit.  I'm going to use the two stroke hose routing with some different fittings.  I attached a picture with the mocked up lower tanks.  I had to re-do the pipe side tank, so I'm going to have ICW redo the other side tank as well.  I used 2" packing foam that I cut to a set size and then custom fit with a belt sander.  I then covered that with gorilla tape for durability.  I think it's going to work out pretty well once he has them modified.  Maybe now I can stop having nightmares about not getting the radiators to fit.   

[umberto]

After the radiators got fitted, I went ahead and tidied some other stuff up.  I've never actually seen the bike together, so I went ahead and slapped the plastic on to see what it looks like.  I'm pretty excited to see it done.

[sandblaster]

Looks great... 

[umberto]

Looks great... 

Thank you! It’s been a fun project so far.

[Green Flash]

yeah looks great!