2000 250/500 steel frame conversion

[BDI]

I like your head stay 

[PowerFiend]

How are you using the stock 500 swingarm, isn't the frame mounting for the linkage off?

[don46]

I reread your first post, bushing the swingarm to fit the bolt, not sure I'd do that, most drill out the rear motor to 17mm and use the 250 swingarm pivot bolt. While it would be easy to build bushings for the swingarm, I don't think it would be so easy to bush out the frame, not to say it can't be done, just seems like more work than its worth.

[wierdo]

nice job!  what is the white box sitting on the front where your number plate would be?

[ZETTNORCAL]

  what is the white box sitting on the front where your number plate would be?

That's an extra gas tank.  I used to have one on a KX80 when I was a young boy so my friends and I did'nt have to come home for fuel. Because if we did our parents would make us come in and eat, stop riding for the day.

[wierdo]

Cool! so what capacity is it and are they still available now? I was gonna make a cradle and strap a couple of 2ltr coke bottles in but that looks safer.

[blueoval]

Is this the Acerbis tank that you are using?   

 http://www.justgastanks.com/store/index.php?main_page=product_info&cPath=360_362&products_id=350&zenid=buc64ho21n9jfshcmliavadli6

[junk man]

from looking at photos of different year kx's it looked like up to 1995 kaw used the same type swingarm as the 500 I used the stock 250 link that was with the frame and used the 500 struts there about 1/2 in. longer than the 250's it all lined up and i think the ride height is ok.   (I am wrong on the years i think 93 was the last year but it looks like they kept using the older chain guide)


When i found out the swingarm bolt was to small for the frame i knocked out the bushings out of an old strut  fitted and welded them on both inside and out on the outside i used a flat stone to smooth it out  with them welded and sandwiched   i hope they stay in place.
it was a lot of work

The gas tank is .8 gal. they don't just bolt on the clamps are for 1970's  forks you have to tweak then a bit and longer hose clamps. the way they work they siphon and fill through your gas cap the transfer hose from the acerbis cap leeks i drilled it out and put an old valve stem from a tube in it  also there's a brake hose issue i cut off the number plate mount and relocated the brake hose guide and put a pice of split loom over top part of hose   Thanks JM

[KXer]

Today got some more work done  polished the swingarm and installed it and installed the forks also found a small problem the throttle cable hits the gas thank should i use a 250 cable   thanks JM

I ran in to the same problem on my 01 steely 500, MY solution (IIRC) was an aluminum throttle tube for a kx500 - grinded down to the shape of a 250 throttle tube, in a 01 KX250 housing, a 500 cable, and then I leaned the carb over just a hair.  no issues since. 

ALSO - I don't recommend the 100* throttle tube spacer dealio from sudco.  I picked one up, and could not make it work as the cable was just not long enough. 

**NOTE** not sure if it is because of my frankenstein throttle assembly, but I have 2 return springs in the carb as it stuck wide open on me at the track 1 day.  First and last time my carb stuck wide open (on a brand new carb!)  I decided, for peace of mind, to add the extra spring.  No issues since, and I like a slightly heavier pull.   

[KXer]

PS - bike is looking great.  I went with the black also, but I also coated the swingarm, tripples, subframe etc.



Stoked we have a steel frame conversion page now, I haven't been on here in a while.

[blueoval]

That is a very nice looking bike KXer!  I want one.

[KXer]

That is a very nice looking bike KXer!  I want one.

Thanks man, I love my bike.  Next mod is to get that compression release.  Its a PITA to kick with the IMS pegs, I think it has dented the top of my foot LoL.

[junk man]

hey KXer  thanks for the info & nice ride
I called studco two times they said on the 90's out of stock 45's had one $9.00 but there's a $24.00 min. so took a look at my 1998 kx125 lots of room on it so i swap the throttle/cable/carb lid with the 500 works sweet
also bought a G force 3 reeds assembly for 500 had the guy send a smaller stuffer #130 looks like it will line up with the 250 holder,I'm waiting on some parts be for i can get it together  but i hung some plastic on it to get a look

Hey KXer can we see a pic of other side also what size tank is that and how's it fit

[KXer]

hey KXer  thanks for the info & nice ride
I called studco two times they said on the 90's out of stock 45's had one $9.00 but there's a $24.00 min. so took a look at my 1998 kx125 lots of room on it so i swap the throttle/cable/carb lid with the 500 works sweet

- Right on.  Take a pic and post it up.  There is definitely more then one way to skin a CR500, I mean a cat (lol)

Hey KXer can we see a pic of other side also what size tank is that and how's it fit

Post more pictures of my bike, I don't have a problem with that haha.



The tank is a HEAVILY MODDED IMS 3.1 (I think).  After trying to heat, and beat the bottom of the tank in I basically ended up cutting most of it out to fit around the head and shorty plug, and then fiberglassed the bottom (I think its like 3 layers of fiberglass) but it holds fuel now.  Then I had throttle cable rubbing issues, and made a 3/8" spacer for the desert tank to sit on (with velcro on the spacer to be able to remove and go back to the stock tank ~ once I fix the stripped nut in it)


Here is my build link on the site to (by the way) http://www.kxriders.com/forums/index.php/topic,4978.0.html

[KXer]

also bought a G force 3 reeds assembly for 500 had the guy send a smaller stuffer #130 looks like it will line up with the 250 holder,I'm waiting on some parts be for i can get it together  but i hung some plastic on it to get a look

What do you mean by smaller stuffer?

On my conversion I had the 01 250 that wasn't enough power and bought the 500 powerplant (which 2 rides later HAD to be shipped to Stewart) so you and I did the conversion from different directions. 

But with mine, I used the airbox from my 250 frame (01), and then when I got the V force reeds from Stewart, it bolted right up to the PWK.  Don't get me wrong, it takes some "Encouragement", but just do it on a warm/ hot day with the bike in the sun for a couple hours so the rubber parts, (READ boot/ intake) get soft and it'll all go together.

If I read it right, you went with a 250 reed cage and the 2000 250's air box?