2003 KX 250 SF Conversion

[umberto]

I forgot to mention that I used the 250 head stays, which are much shorter than the 500 stays.  You will need to re-bend them to move the frame section of the head stay over, but they are handy for holding the steel frame section in place as you measure and mark.

[umberto]

Vibration is a big issue with Goliath, so I thought I would add some anti-vibration bar ends to see if they would help.  I had really good luck with the Best Dual Sport Bikes dead ends, but I've wanted to try some that I saw on Rocky Mountain because they seem a lot more compact. These are made by Faast company:



I added some ODI bolt on grips; I figured it would be better to use them instead of gluing over the bar ends.  The thing I like about the Faast bar ends is that they fit flush with the end of the bar, and the grips go over them:





I could not get them to work with the Pro-Taper Fusion bars I had on the bike (and they were bent from the big wreck in May), so I swapped over to some different bars.  Hopefully I will be able to give a full ride report on Sunday.

[umberto]

I took Goliath over to Lake Draper today to test out the bar ends.  It was a beautiful day in Oklahoma City, 65 and light winds.  The riding area ran out of permits, so it was a free ride day.  The bar ends did a nice job of deadening the vibration, but were not quite as good as the Best Dual Sport Bikes dead ends.  Still it was a big improvement.  We rode about 22 miles today, and the new tank made a big difference in fuel range.  It's nice to ride and not worry about running out of gas.

Here is Goliath before I cleaned him up:



And here he is after a bath.  



I really enjoy riding this bike.  I thought a 500 would suck in the woods, but it just chugs along.  I'm glad I took it today for sure.

[69HemiGTX]

Howdy from a fellow Okie!  Did you ever get the powder coating done?  I must say your bike is one hell of a build.  I think it needs a paddle tire and trip about 120 miles up to the northwest. 

[umberto]

Howdy from a fellow Okie!  Did you ever get the powder coating done?  I must say your bike is one hell of a build.  I think it needs a paddle tire and trip about 120 miles up to the northwest. 

Thank you the complement 69HemiGTX!  I'm still waiting to powder coat my frame and get the compression release fitted by Larry.  If I could just stop riding it for a little while, maybe I could get it done.   

I've never actually been to Little Sahara, but it looks like fun.  I grew up in Southeastern Oklahoma near Fort Smith, Arkansas riding in the mountains.  When I was a kid and had a four wheeler, it was too far of a drive, and I guess I just never thought about going as an adult.  I figured it wouldn't be much fun riding in sand.  After seeing people having fun with dirt bikes on the sand other places, I really want to go now.

[umberto]

It's kind of a gloomy day in OKC today, so I figured I would try a project I have been putting off for a little bit.  I would like to have a little bit longer brake lever, but I couldn't find one specifically for my bike.  I was able to fit a Tusk lever to my 2004 KX250 (using the 2004 pivot bolt), but it hits the clutch cover a little bit and sticks out a tad more than I would like.  



Thankfully Tusk makes replaceable ends that you can buy for $19.99.  They bolt on to the Tusk lever, but will not bolt to the stock lever without modification.  
I also picked up the replacement clevis for $12.99.  It says it only fits the 2005 and up, but it fits my 2003 and 2004 just fine.  



In order to get it to fit, I got out my Dremel tool and cut a small trench in the top of the lever to fit a small ridge machined into the bottom of the Tusk lever.  Nothing fancy, just ground until the bolt hole lined up.



I polished the lever up with some Mother's Mag and Aluminum polish, gave it a quick wax and installed it on the bike.  I really like how it turned out.



It gives me the that little bit of extra length I was looking for as well.  Here it is with the lever from my 04.

[sandblaster]

Looks good 
If you don't mind, I would like to document what you did over at KX Guru...

[umberto]

Thank you Sandblaster!  I actually starting thinking about it while reading your KXGuru post about putting the 450 brake lever on a KX500. Before that I had never really thought about how small and short the levers were.  Please feel free to post it on KXGuru.

[sandblaster]

Done deal

[umberto]

Ever done one of those mods that you wish you would have done from the beginning?  I purchased a two piece cover from Sandblaster, and man am I glad I did.  Not only does it look trick, it also solved a really annoying issue with my oil fill.  It uses a KX450f clutch cover, which has the filler built in.  Being on the clutch cover means that it is no longer right under my pipe, so I can change my oil without removing my pipe now!  Thank you Sandblaster!!

[reklessj]

Ever done one of those mods that you wish you would have done from the beginning?  I purchased a two piece cover from Sandblaster, and man am I glad I did.  Not only does it look trick, it also solved a really annoying issue with my oil fill.  It uses a KX450f clutch cover, which has the filler built in.  Being on the clutch cover means that it is no longer right under my pipe, so I can change my oil without removing my pipe now!  Thank you Sandblaster!!

Sweet!!!!

[umberto]

Did you order one too reklessj?  They are really well done pieces.

[mikectanker]

that 2 piece is the only way to go. I  might copy that longer brake lever idea if I ever get time.

[reklessj]

Did you order one too reklessj?  They are really well done pieces.

No unfortunately life bit me in the ass (Prius motor). So I won't be getting any of this batch. But I will next time round

[umberto]

Ever since the big wreck last year, I've been a little uncomfortable with Goliath.  I just have a hard time not thinking about the forks turning in the triple clamps, and even though I swapped out for the 2001 models, it's still in the back of my head.  I have been looking for a set of aftermarket triple clamps with a little more clamping surface, but no one made them for anything earlier than 2002.  I always remember Foxx's advice about watching eBay, and the other day it paid off.  I saw an ad for a set of upper clamps for a 2001.  They were gold, but at least they were the correct model year.  In the ad it gave a phone number to call if you had questions, so I gave them a call to see if they had any other clamps for sale.  In turns out the company selling them was Topar Racing, which makes the case saver for the KX 500 that several guys have on their bikes.  I spoke with Henry, and he hooked me up with a set of triple clamps and handle bar mounts for $236 plus shipping.  They are coated with a substance that looks like anodizing, but is more fade resistant.  It's called Endurocoat, and was originally developed for Navy Seals.  I talked to him on Wednesday, and he shipped them out to me on Thursday.  I got them in today, and can't wait to get them mounted.  They are really nice for the price, and very beefy.





Here is a link to their site if you are interested.  Ask for Henry.

http://www.toparracing.com/