Can I join the club?

[gwcrim]

Just had a 2002 KX250/500 dropped off at the house this AM.  Not an aluminum frame, but a hybrid, none the less.  Bought it from a guy here that goes by 'racemx'.  It's in need of a bit of TLC but the price sure was right.

I'll be calling Service Honda for a pipe and looking for a powder coater to do the frame.  I have lots of goodies on my '89 500 engine that will be transferred as well.

May god have mercy on my soul!

[AJ]

cool!

[maddoggy]

good luck with it. that bike looks like alot of fun. it doesn't look like it needs too much tlc to get it whipped into shape. MADDOGGY

[BDI]

If you built it from scratch yourself you would be an honorary member, for now your just a prospect. 

[demographic]

Didn't you used to have a Rocket Science Racing perimeter framed KX500 a while ago gwcrim?

[gwcrim]

Not me.  I'm not a rocket scientist.  I just play one on TV.

[gwcrim]

Just ordered a shiny new Service Honda pipe for my monster.  Had a nice talk with Stewart too.  Gotta get moving on this thing.  Found a powder coater that can do Kawi green for the frame but he's got a 4-6 week back log and I don't even have it ready to go.

I'll have the tabs for the pipe welded ASAP and then strip it down.  Spring will be here before ya know.

[gwcrim]

Got the pipe today.  Nice pipe it is.  Initial fitting is pretty good.  I have a copper 180* fitting to deal with the coolant intake line.  Not the most beautiful thing in the world, but certainly sufficient for the time.

The biggest headache looks like it will be the stinger.  At first glance it appears that the shock reservoir is about 1/2-1" too low.  Would be great to just move the upper shock mount up by 1".  That would lower the bike and I'd like that too.  But that's probably more of a job than removing the stinger and rewelding it at a slightly lower angle.

I'll post pics later.  I'm not going to rush this job and screw things up.

[gwcrim]

Other minor issues are that the oil filler isn't going to fit, the rear brake reservoir hits, and the bend on the silencer isn't correct. 

I know..... the pipe wasn't designed for this bike.  I'm not complaining at all.  It's far closer than anything else.  Where there's a will, there's a way.

[love2ride450]

Hey guys, just joined the forum today! I heard good things about this site on thumpertalk, and I needed some info about a K5 project, so here I am.

I was curious if you wouldn't mind letting me know how much AJ charged for the pipe? I have a 2003 KX250 that is begging for my 86 K5 engine, and as far as I can tell, the pipe is going to be the hardest thing to get right.
Thanks,
Josh

[don46]

Didn't you used to have a Rocket Science Racing perimeter framed KX500 a while ago gwcrim?

I had a Rocket Science frame, never really liked it, the bike sat too tall, it was probably another 3" taller than a stocker and as for handling it was just a 500 with different plastic. The true hybrids handle much bettter and even sit better and the rocket science kit wa about 3k, so no real bargin there

[gwcrim]

Hey guys, just joined the forum today! I heard good things about this site on thumpertalk, and I needed some info about a K5 project, so here I am.

I was curious if you wouldn't mind letting me know how much AJ charged for the pipe? I have a 2003 KX250 that is begging for my 86 K5 engine, and as far as I can tell, the pipe is going to be the hardest thing to get right.
Thanks,
Josh

The pipe was a about $400 and that was with the quieter, more expensive Q silencer.

We're stretching things by using that pipe on a different chassis but the right engine.  An 86 engine may be quite different.  Could be more trouble.  Lots of cutting and welding.

[gwcrim]

I was up until who knows when pondering the pipe.  I took the shock off and the pipe actually fits pretty well w/out it.  Now to get rid of that pesky reservoir.  I'll see what I can find in a shock w/a remote.  I don't want to cut up a perfectly good pipe and the rear shock seems to be leaking a bit of oil.

[gwcrim]

I got the Service Kawasaki pipe stuffed in and it will fit without denting or cutting it.  Unfortunately, the reservoir on the shock hits the pipe.




This is the shock on the bike.  I've never seen one with the schrader valve that hung down below the reservoir body.  This takes up 5/8" where there's not any clearance anyway.  Even with a recessed schrader valve there will be interference.  I believe I can probably notch the body of the reservoir.  Anyone know anything about this weird schrader I have?



To mount the silencer, I'll weld a nut under the subframe for the forward mount and fab a little hangar for the rear.  The fender will need a tiny amount of trimming.



Other than mounting points for the tabs on the pipe to the main frame, that's all it'll take to fit it.  (I hope.)  Fabbing a coolant line to run from the pump to the jug may be challenging.  I have a few ideas but a Service Kawasaki hose set sure would work too.

[doordie]

Bent it were stinger (bleedingpipe) begins downwards, and bend up mufflerpipe with a sharper angle were stock bend is.
This rerouting will make muffler to fit in higher excisting hole in subframe.

Just my 2 cents!