my 03 kx 250/500 build

[Suva]

You didn't have issues with the tire rubbing it?

[The Flyin Hawaiian]

Nope, everything clears.

[Suva]

nice

[jrowley85]

first off i love this site, lots of good info, but to get down to business is it better to try and find a donor bike? or to piece one together off of ebay?? ive been looking and cant seem to find a bike thats not way to expensive considering what im going to do to it ... and if i do piece one together how much of my original 500 can i use? i know i can get a frame, shocks and all that for a decent price but the rims are just way to expensive, might as well buy new! also i have heard of a few guys using the stock 500 swing arm, is that a good way to go or not?? will it even bolt up with the 250 linkage?? as you can tell ive never built a 250/500 conversion before.. thanks for the help

[The Flyin Hawaiian]

I lucked out and already had the 250. The 500 fell into my lap after my brother inlaw lightly seized it and wanted to trade me even up for a DR350/435 dualsport that I had. I probably have around $500 into it after selling off the 500 chassis. Still have a few bits left that should knock it down to a couple hundred. Again, I was very lucky. I only used the engine, ignition and a few miscelaneous bolts and brackets from the 02 500. Everything else was from the 04 250 with the addition of a 96 KX125 carb top and cable. 91-94 KDX250 carb intake and the Service Honda KX500AF exhaust and FMF Q silencer. I did use the 500 throttle. The easiest way is to have both bikes and not sell off anything until the project is done. Ive seen 03 250s for as low as  a grand and the 500s run from $800 to $4500. I wouldnt use the 500 swingarm, it would most likely change the leverage ratio of the shock. It wont even come close to working on a 04 250 due to a change in the linkage arrangement for that and following years.

[jrowley85]

thanks for the info Hawaiian!! well then since thats settled was the build on the 04 as simple as the builds i have been reading abouton this site with the 99-01's?? and i already have a great running 99 kx500 that i fell into when a guy wanted to trade it for my 01yz250... i think i got the better deal .. the problem im finding is the 250's are just so d**n expensive, its a good thing im in Afghanistan right now or i might get impatient looking for the right bike.. also what kind of mods did you need to get that service honda exhaust to work?? i have been to there site and i cant even find where they sell them, and i know i would not want the Q silencer... i like being heard!!!! do you know of any good sites to look for bikes other that craigslist?

[The Flyin Hawaiian]

From what it looks like it seems to be about the same amount of work to do either one. The headstay has to be centered on the 03/04 frame for tank/petcock clearance. The headstay mount on the head needs to be shortened and a new mount hole drilled. Everything else is more or less the same. The pipe pretty much bolts right on. I clearanced it slightly to clear the coolant hose better on the right side of the cylinder. I didnt alter the pipe just so it can be replaced easily. The 03 frame already has a rear mount for the stinger. The 04 frame doesnt and needs to be welded on. I welded a mount to my subframe. Its been over a year now and it hasnt had any issues, very reliable and handles great! Took a little while to get the jetting straightened out and fine tune it. If you have to run a big tank you need to use a 05-07 KX250 2stroke tank. The 03-04 IMS/Clarke tanks will not fit. Same thing with the 03-07 KX125 tanks, they are the same as the 03-04 KX250 tank.

[jrowley85]

WOW!!! your a wealth on knowledge!! i cant wait to get this project started!! I will be going to you for input since you know so much if you dont mind? im an alright welder for what needs to be done, but how hard is it to get the head stay cut and bead blasted?? is that somthing i should just send out to someone?

[The Flyin Hawaiian]

Sorry for the late reply, I just saw the post. I had a machinest friend cut the head-headstay down and redrill it.

[Ims Roll]

thanks for the info Hawaiian!! well then since thats settled was the build on the 04 as simple as the builds i have been reading abouton this site with the 99-01's?? and i already have a great running 99 kx500 that i fell into when a guy wanted to trade it for my 01yz250... i think i got the better deal .. the problem im finding is the 250's are just so d**n expensive, its a good thing im in Afghanistan right now or i might get impatient looking for the right bike.. also what kind of mods did you need to get that service honda exhaust to work?? i have been to there site and i cant even find where they sell them, and i know i would not want the Q silencer... i like being heard!!!! do you know of any good sites to look for bikes other that craigslist?

try "bikefinds" if you don't mind driving near by you will probably have way better luck finding one. found my 01 K5 on bikefinds. had to drive 8 hours none stop but oh well

[81cr450]

My vote as well, buy 2 bike's, the 250 & 500, you can usually get one around a grand a piece.   From november to february the deals are the best. Then ebay what you dont need it will near zero the cost.

Bike finds is sweet, also try CL & one of my local newstations has a classifieds section that been the where the best deals have been. You can stuff a bike in your trunk which helps with gas if you do have to drive a-ways

[The Flyin Hawaiian]

I parted out the remains of the 500 and knocked the cost down to around $500! I as lucky since I already owned the 250.