2003 KX250 / KX500 hybrid.

[love2ride450]

My Dad gave me his old 86 KX500. Running bike, I've ridden it a few times myself. So, naturally I started searching for a newer bike to shoehorn the motor into. I spotted a '03 KX250 in great shape, ready to ride, for $1300. It is a good deal in my area, so I picked it up. Now, I join this site, and start poking around, and I see a lot of negative talk about the '03, and so far I haven't really heard why?

I am sure it has been discussed, but I am thinking I'll push this forward, so what are the negatives?

[sintax]

they really are kind of a one off year. A lot of 2003 only parts that only fit that bike, not like the 99-02 bikes or 04 and later bikes.

as for the 86, i'd leave that guy stock and enjoy it for the old bike it is. I'd just find a 97+ engine to swap into the 03 if you wanted.

[don46]

If you have a whole rolling chassis I go for it, but if I was going to put one together with parts it would be either a 99-02 or 04-06 chassis. The 03 will be a great bike especially since you already have it.

[love2ride450]

Okay, I can handle that. I was afraid there was something about the bike that made it handle poorly, or too cramped for the k5.
Sintax, why do you suggest using a 97 and up engine? I haven't researched it myself, but I always heard that the 86 engine was the stronger runner.  I know it's a chrome cylinder, which is a mixed blessing, what other negatives are there?

[don46]

The biggest negative is that many parts are no longer available, such as all the KIPS drums and shaft, 86, 87, and 88 used the same then the big change in 89. The clutch doesn't work as smoothly as the 89 up. Not really sure why Sintax suggested the 97 up motor, there really aren't many differences, at least any that would make a huge difference.

Just thinking about it, and not very hard, I might like the earlier engines better, maybe. Kawasaki didn't really change the motor for about 15 years, they used the same tools in the manuf. process, so it would stand to reason that the newer motors might not be as close tolerance wise as some of the olders ones due to worn out tooling. Like I said thinkiing about it but not to hard.

[love2ride450]

Thanks Don, I think it will make a nice bike, and I intend to keep you guys posted on the progress. It's going to be a slow go, and I may not even finish it this year, due to financial stuff, and I want to do a nice job. I'm going to ride the 250 as is while I go through the K5 and gather some parts for the build. 

[sintax]

The main reason i was suggesting going with a newer motor was strictly for parts reasons. I know its gotten harder to find late model KX5 stuff, let alone early factory parts. As for the 97+ deal, I knew the last major change for the bike was in 97, but did not think there was any engine changes made since the early 90's, but figured you might have a better shot at getting a less abused engine had it been made in the last 5-6 yrs

[The Flyin Hawaiian]

The 03 and 04 KX250s are very similar, I have both. The 04 doesnt share much with the 05 up, I also have a 07. The biggest differance between the 03 and 04 is the rear suspension linkage. The 03 is a bit better in rocky terrain due to its linkage arrangement. If you want to get technical, the 03 is a single year bike and the 04 is a single year bike. There were major changes in the frame, chassis, and engine in the 05 to 07 KX250s. The front brake on the 04 got the Honda style brake hose routing and does have a little better feel. The power on the 04 is better, more smoother delivery and more low end power. That wont make a differance since you are thinking of swapping a 500 into it. I have a 02 500 and was thinking about swapping it into my 04 chassis in the future.

[doordie]

Here is my new baby!

Revloc clutch
Rinopipe
Spacers made for fitting old wheels and brakerotor
on.on.....

[The Flyin Hawaiian]

Looks great! I was debating about doing this since I have an 02 500 and a 04 250.

[Dutch-K5 Fan]

Great bike Doordie!!!!
Is that a special Rino pipe or one thats modified???

Dutch

[don46]

doordie,

Braking makes an oversized rotor that will fit the old style hubs, but is the same diameter as the newer rotors. I too have a boat load of older hubs and am using the wheels on newer framed bikes, powerful brakes for my application aren't that important so i cut down the caliper to fit the older style rotors. If you want the part number I can dig it out and get the numbe off it.

[GDubb]

Did you build this doordie? How'd you sneak this in under our noses? Nice bike!

After seeing all the cool toys you hybrid and AF guys have come up with, you better watch out if I ever end up with some money!


-G

[doordie]

doordie,

Braking makes an oversized rotor that will fit the old style hubs, but is the same diameter as the newer rotors. I too have a boat load of older hubs and am using the wheels on newer framed bikes, powerful brakes for my application aren't that important so i cut down the caliper to fit the older style rotors. If you want the part number I can dig it out and get the numbe off it.

Yes plz!

[doordie]

Did you build this doordie? How'd you sneak this in under our noses? Nice bike!

After seeing all the cool toys you hybrid and AF guys have come up with, you better watch out if I ever end up with some money!


-G

No,I have some luck in my life and bought it in this conditions except of wheels.

It have:
A 2004 engine (20 hours)
A 2003 KX250 frame (20 hours)
Modded SM-suspension
Another trippleclamp
Revloc clutch
Special made Rino pipe (very rare)
Vforce 2