Looking for input on stuffing a 500 into a 95 kx250 frame

[bigbellybob]

You better have your heat and wire speed set right, close wont cut it on this.

i would love a new miller with auto-set. you just select the thickness of you material instead of the heat or voltage. then the welder automatically provides the wire speed. im a tard when it comes to setting up a welder and i think even i could weld with the new millers.
http://www.millerwelds.com/swf/swf.php?swf=mm180autoset_550x400.swf

[Goat]

I've read about those welders a month or so ago. They sound idiot proof lol. Just the mig for me. I have a hard time welding with mig. I can arc weld great though.

[kwakman]

Don made a good point.if your frame is a 95, get the appropriate parts and modify them from there.if you dont know the interchangerbility of the 250 yrs, it will make life a lot easier in the long run.BDI's peri frame 500 is the dogs danglers, so if he says you'll need to mod everything, I'd believe him.....As long as your ready for the long haul, go for it......Kman.

[Goat]

Thank you very much everyone. Bike is on hold for a while. In the process of finding a new place to live. Hopefully with a bigger garage and a 220 outlet for my Lincoln stick welder from the 60's

[Goat]

Been thinking about this project a lot lately. I have had plenty of seat time on my K5 and it still feels like a tank to me. So I want to tear it down and put it in the 250 frame before I build another quad with it lol.

Things I need to know are: What year/brand CR5 pipes to use? What year parts interchange with 95 KX250? Do I need a different intake boot to line the carb with the airbox?

[Suva]

Been reading up on the subject a lot for my own upcoming conversion.  Seems the '89-up cr5 pipe is the one to use.  The rest, ?  Wanting to use my k5 swing arm, would rather have the extra length (small as it is) and somehow not drilling out my engine makes me feel better.  You ever decide on that issue?

[Suva]

Well, after ripping both bikes apart last night, length issue is moot, but the k5's sa is noticeably lighter than the 01 250's is

[junk man]

goat what 250 parts do you have. If you use a 95 frame you will have to use 94-98 body parts tank plastic seat etc. if your going to use all the 500 parts you can i can list the 250 parts you will need
note i used a 2000 frame and was going to use 98 body parts they don't interchange

using 500 swing arm its no big deal if you can weld good or have a new swing arm bolt and two shouldered washers made at a machine shop. the swing arm bolt is almost to short if you make a longer bolt you can use two stepped washers and bolt it all together the next thing you have to do is make two spacers for between the engine and swing arm ( i use two grade 8 washers on each side) the 500 link mounts between the engine and swing arm so you will have to fill in the gap. I used the stock 250 link but used my 500 struts.the 500 struts are 1/2 longer than the 250's  this will give you correct ride height and the  last thing i used 250 spring i tried my 500 spring way to stiff     

hope this helps out JM

 

[Goat]

Thanks Junk Man.

I didn't do any cutting yet. Tried to fit what few parts I do have and found out quite a few parts I got with the frame are not for that frame. Rear shock in perfect condition is the exact same as the one on my 500 and will not fit in between the upper mounting tabs. Linkage is identical to my 91 KDX and will not fit. So this project is turning into a bust.

I'm now thinking about buying a 2000ish + complete 250 for the donor and sell the 250 engine or build another quad with it. Not sure. Don't have the kind of cash I need for the project at the moment. Also looking to move a couple hours south to find a better job as well.

If anyone is interested I could package the frame, and subframe up and ship them. Make me an offer.

[junk man]

Goat if you have a downer makes things a lot easier   maybe one day  JM

[sandblaster]

Sorry to hear your not going through with it but I ran into some money draining issues on mine as well.
I just need to get through this summer and I should be able to give it a go again.
Getting a complete bike with a blown engine is the way to go.
So far I've made a few bucks on my project selling what I didn't need from both bikes.
In the end it will cost me some because of the engine work I'm having done but still it is by far the least expensive way to go.

[Goat]

Eventually I'll build one. Hopefully next winter. My 500 is still running great and the kdx quad is holding up to my beatings so at least I have stuff to ride.

[sandblaster]

You'll do it.
My fab skills are not very good but I have done pretty good so far.
After seeing what you have done I know you will have no issues.

[Goat]

Thanks Mike. I'll be contacting you as soon as I get back to work. Hopefully in the next couple weeks.

[Suva]

You'll do it.
My fab skills are not very good but I have done pretty good so far.
After seeing what you have done I know you will have no issues.

+1^
so far with mine going fairly easy (minus bearing issues) with a touch of ingenuity an tool know-how (not that I'm real far into it).  Engineering degree not required...