KX500 hybrid suspension.

[cutting torch]

Now that I have covered my insanity with power tools, i'll cover the rest.....

I needed steering stops. The KX250 stop would not work with the KLX450 triples. The 250 stop is the tab on the front, and the 450 uses the frame on the back for stops:



I needed to duplicate the 450 frame to get my stops:





I set the final clearance to match the fork to frame clearance of the stock 250:



In doing that, I lost 12 degrees of sweep compared to the 250, and 6 degrees from the 450. I can live with that.

torch

[Goat]

Coming along nicely. Looks great. Any power tool is dangerous if you don't pay attention to what you're doing. Nice use of the bat Keep up the good work.

[crazyolbastard]

I got a set of tripple clamps you may want to use on this, unless you have an idea on how to make them work for my 91 kx500 with a 96 front end.
I got the set cheap and they fit a 2003-2007 kx125/250 and a 2004-2006 kx250f.
The upper clamp area is too big for the forks I have.
I`m not sure if I can remove some materail from the cener where the bolts go thru and keep it`s rigidity.
Second problem I have is the upper bearing.
I have read that the stem can be pressed in n out but anyway, the upper bearing on the new set of clamps is way too big for the kx500.

I can send exact specs if you wanna brainstom for a fix.
If you want this set of trip clamps I can sell them CHEAP.

[cutting torch]

I got a set of tripple clamps you may want to use on this, unless you have an idea on how to make them work for my 91 kx500 with a 96 front end.
I got the set cheap and they fit a 2003-2007 kx125/250 and a 2004-2006 kx250f.
The upper clamp area is too big for the forks I have.
I`m not sure if I can remove some materail from the cener where the bolts go thru and keep it`s rigidity.
Second problem I have is the upper bearing.
I have read that the stem can be pressed in n out but anyway, the upper bearing on the new set of clamps is way too big for the kx500.

I can send exact specs if you wanna brainstom for a fix.
If you want this set of trip clamps I can sell them CHEAP.

Thanks for the offer, but all the suspension stuff you see in the pics will stay on the hybrid. I didn't rob my KLX450 to fit all the parts, I got all the parts on ebay just for this build.

torch

[Motorrad]

Hey torch.  In the process of doing the same thing to my 91k5.  08 kx450f components on mine.   

Curious if you could give us an update on the rear shock.  How did it work? Ratios way off?

[cutting torch]

The ratios were so close to identical that I don't think there would be a noticable difference in suspension feel.

I had a post about it on TT, but that was during the Huddler crap, so I think that thread is gone.

torch