2003 KX 250 SF Conversion

[umberto]

Good planning. I wasn't going to do an auto clutch originally, until I rode at Danger's place and had to kick start my bike 500 times. I also wasn't aware that you could use your clutch lever with a KX500 EFM clutch. I'm glad you guys started talking about it, because I love the auto clutch in my 250.

[umberto]

I finally got my spacer back from my buddy.  He was swamped at work, so it took him a lot longer than he thought.  I should have it tomorrow, so I can get my clutch on this weekend.  I'll keep you posted.

[umberto]

Man, it's been a long summer.  Understaffed at work, Lunchbox qualified for summer swimming sectionals in Lincoln, Nebraska (proud papa moment), and a quick family vacation.  Not much time in there for projects.  Anyway, I used my Mexican drug smuggler tunnel at work to finally escape and get Goliath back together.  I misunderstood the EFM clutch guy and actually had it installed correctly but I thought I was missing a washer.  Nope, I just wanted to pull it apart one more time I guess.    I got the clutch installed, and ran into an issue with the brake lever hitting the clutch cover.  I made a spacer for it, re-engineered the pivot, tweaked the clevis, and got that installed as well.  It was time for a ride around the block!

It takes a little adjusting of the lever, but once I got it right the clutch made a HUGE difference in the ride ability.  It will sit and idle in gear all day long (not recommended by the way), and the clutch pull is beyond light (1/2 a finger).  I only got to ride it around my neighborhood, but it feels like it hooks up at pretty low rpm.  I am beyond pleased with the clutch.  I just wish I would have done it sooner.

I'll post some pictures of the brake pivot later in case anyone wants to install an EFM on their bike.

I'm working on getting all my picture links fixed as well.  Unfortunately I have about 400 links to go through.   

[zz3gmc]

Hey Umberto! Im building another 04 250/500 this time with a 87 engine. I picked up a blown up 04 250 this summer with plans to build another 300 for the wife but that changed when we stumbled upon a nice 87 500 engine at a vintage bike swap meet for $150! The wife is getting her 500 finally!

[umberto]

Hey Umberto! Im building another 04 250/500 this time with a 87 engine. I picked up a blown up 04 250 this summer with plans to build another 300 for the wife but that changed when we stumbled upon a nice 87 500 engine at a vintage bike swap meet for $150! The wife is getting her 500 finally!

Wow, that was a steal!  I can’t wait to see your progress. What do you have planned for the build?

[zz3gmc]

Very similar build to my bike just tailored to her. Whatever we learned building and improving mine over the years will be applied to hers. A few things will be improved upon. The plan is to make it as smooth as mine if not smoother if possible. She wants to race it next season at a few select enduros and a extreme enduro in PA.

[umberto]

I fixed all the links in this thread using the trick Larry posted. Photobucket pic links can be fixed by adding ~original between .jpg and the [\img] in the link to the pic. It fixed most of the pictures, I’ll try to get back to the others as soon as I can.

[umberto]

I fully plan on tearing Goliath down at some point to have Larry install a compression release, and so I can have the frame powder coated.  Right now my 250 is in a million pieces as I convert it to a 2017 KX250F, so Goliath is my primary ride.  I bought some different suspension for my aluminum framed bike (more on that later), so my Stillwell Performance suspension was just sitting and collecting dust.  I decided to swap it on to Goliath, and let my son have the KYB kit suspension I had installed because the SP stuff works just a little better.  I installed the forks, but wasn't able to use the shock because of the difference in length between the 04-07 bikes and the 03.  I just stayed with the KYB shock for now.  Anyway, I am pleased with the look and how well the two ends work together.  

I also picked up one of the TSR exhaust valve covers.  They are really well made pieces, and look way better than the ratty plastic stock pieces.

[umberto]

I went riding yesterday with my cousin.  The riding area was really soupy, and we were in and out of the trees all day.  I'll say it again: If you are riding your KX500 in tight terrain, the EFM clutch is worth its weight in gold.  I never stalled, and the clutch softened the hit just enough that I could keep the bike in a lower gear.  I felt like I was riding my 250, minus the fuel economy of course.   

The fork swap worked out better than I could have imagined.  I'm not sure why, but they seem to be even more plush on the big bike. 

Anyway, here's a picture of all the mud I brought back with me.  It took us 2 hours to clean up the bikes.   

[Danger4u2]

I worked all day, where did you go?

[umberto]

I figured you were still working.  How's the job coming? 

We were going to ride on some land our other cousin owns, but he bailed at the last minute so we ended at Draper.  It was a pretty much under water.  We rode a bit of the red, black (we turned right after the tires), green, and the grass track.  We rode 23 miles, and neither one of us can move today.   

[Danger4u2]

We finished around 1 yesterday. Off today.  Riding behind the shop this afternoon.

[umberto]

Sounds like fun.  The weather couldn't be better right now.

[umberto]

With my aluminum conversion done and my kids off at college leaving me with a lot of time, I am going to finally finish the last few items on Goliath.  Step one was to get one of Larry's decompression levers for the head.  I always had an issue with having the bike down long enough to get the head modified, but I could not find an 88 head.  I check eBay every few days looking for one, and for almost three years I have had no luck.  Yesterday I finally found one in excellent condition.  As I looked at it I realized the ad looked familiar, and sure enough it was one of Sandblaster's ads.  We swung a deal, and it should be on its way to Larry next week.

I am also going to be cleaning up the welds on the frame where necessary, and will be sending it off to powder coat.  I going to go with a bright silver, like the 2007 two strokes.  If anyone knows of a good powder coater, let me know.  I only have one close to me, and I think he is a bit high on the price.

[sandblaster]

My last frame cost me 225 to have it stripped and coated in Kiwi Green.
How much is your guy asking?