2001 RM250/ 1994 KX500 conversion. The "Kawasuki RM500"

[mikectanker]

Front end ordered tonight. all ebay parts
-Rebuilt stock 2006 RMZ450 forks which came with .47 springs. I'll see how they feel and maybe revalve, but atleast I have my correct spring rate. pics on ebay looked great..... $310(could have went cheaper but these seemed pretty nice)
These forks had a very good rating according to the MXA test back in 2006
-2006 rmz450 front brake assembly $70
-2006 rmz450 front wheel with rotor $129
-2006 rmz450 front axle with spacers and dust covers $20

some other parts added in the past couple days
-green anodized pivot levers $28.19
-green chrome zip ties $10

[mikectanker]

Just wanted to say thanks to Sandblaster for the 2 piece clutch adaptor and the link to making it work
http://www.oem-cycle.com/forum/viewtopic.php?f=5&t=334&start=80

[mikectanker]

Here is a great site to look up fork info for putting newwer stuff on an older bike. http://www.tech-care.com/

I knew the 2008 rmz250 forks fit on my build since I tried it out.
I looked up forks and tests on the site. then looked up tests of the bikes focusing on the forks.
Picked 2006 rmz450 front end based on spring rates, fit, condition, and price on ebay.
The 2006 uses  basicaly the same 47mm twin chamber showa set up that is on my 2008 rmz250.

I wish I knew if sss forks would work. that would have cost a bit more.

[mikectanker]

Stock 2001 RM250  kyb shock boxed for shipping. Glad I saved the 5.6 spring off of my old 1993 CR500. Sending to Pro Action
$225 plus shipping

Going to try the 2006 rmz450 forks stock before sending them out.

[sandblaster]

Post some pics if you have some.

[mikectanker]

Case has been machined for the swing arm bolt. Went to the shop to look it over.
Sprockets are aligned perfect.(I did have to play with the positioning of the stock shims to get it right)
They are going to try to use the stock rm250 front motor mounts.
Just have to cut and reweld the bottom mounts.
Front and bottom mounts will need shimmed up.

Looks like all I need to do to the service honda pipe is cut and reposition the front mounting tab. Then fab for the silencer to line up and slip on.

I ordered a compression release from the Stihl dealer today $16.
Ordered a tusk oversize front rotor kit $110
oil seal kit$15
devol enduro skid plate $83.50

[mikectanker]

Post some pics if you have some.

I am waiting to post more pics. My 1 1/2 year old
Was addicted to tractor videos while I was on the road
In the big truck last week. Data limit is close. Resets on the 7th.

[southwick]

So, how's it coming along? Lots of pics needed, I'm considering doing a similar build myself, RM2250 2007/KX500 engine, so any details much appreciated!

/Lasse

[mikectanker]

Just got home from being on the road in the big truck all week.
Also holding up the bike build is the fact that I am getting married in 8 days.

The shop should have the two piece clutch cover done.
Engine mounts are done.

I'm waiting on my cylinder from Eric Gore. I think it shipped a d he got it done faster than expected.

I need the cylinder to make a new head stay and modify the mounts on my pipe.

I am waiting on the compression release from the Stihl dealer still.

Got the shock and forks wrapped in green chrome.

Tons of new parts pretty much all in.

I need to contact rekluse and order the right clutch with the right springs.

Need to contact Scott's and get a green steering damper kit.

Need to ride the bike and figure out what bend of fast flex bars to get in green with the bent crossbar for the steering stabilizer. 

At some point I am going to get more pics up.between the road and wedding.  I'm not expecting to have it finished until after the 20th.

And I have a possible deal on another blown up KX500.

[mikectanker]

Got a complete 1990 Kx500 for spare parts today from a local shop.
Motor in it is completely disassembled and needs a top end job. Crank is out and rebuilt. Has a v force reed cage.

$250 for the whole thing.  So now I've got 2 rolling chassis to get rid of.

I still don't have my cylinder back,  but I dropped the spare off at the fab shop. I just need to get the head stay and exhaust fabricated to work. Pics coming some day.....

[mikectanker]

Here's the front mount. Used stock mount just shimmed.


bottom mount. cut off rewelded new tabs, and shimmed.


engine in frame with 2 piece clutch cover


shock before plasti coating yellow spring to black

[sandblaster]

How purdy is that 

[mikectanker]

How purdy is that 

Pictures don't show how good that stick on green chrome really looks.

[mikectanker]

Finished shock


Finished forks

[mikectanker]

I got the bike back from the fab shop last week.
Got the front end on but had to  peel some of that green chrome vinyl off of the forks to fit in the triple clamps.  At 1am I never thought about prying the triple clamps open a little.

I never had to cut the pipe but I will need to dent the back side of it to clear the water spigot. They modified the front diameter of the silencer to fit in the pipe.

Got my cylinder tonight.  Looks good. UPS managed to beat the hell out of it on the ride home and the 1mm head gasket got beat up a little.

The wedding held things up, and now I have a temporary health problem keeping me out of the garage. Not sure when I'll get it done, but I have everything I need to put it together and ride.