kx500sf project

[jonny500]

i had the swing arm bushes shortened to 45.2mm

[jonny500]

i had to modify the bottom mount slightly so it would take the bolt

[jonny500]

the engine went in fine

[jonny500]

i didn't fancy using the original front mounts so i made some more using thicker steel and a bit bigger

[jonny500]

they fit ok too

[Kawasakifreak]

   The reason I came to this site was to find info on kx500af's and sf's. I found what i needed. it is now my turn to put some back.
   I have decided to do an 99-02 250/500 conversion as it is the most straight forward and if my memory serves me right the 99-02 250 wasn't a bad bike. Over the past few months i have been collecting the parts together. for the engine I purchased an 89 kx500 with damaged clutch basket for ?700, I  figured it didn't matter what year as they are all the same and i planned a complete rebuild. I put a new clutch in it and rode it a few times but ended up seizing it up. So i pulled the motor and sold the chassis parts on ebay and got all my money back plus more. i managed to buy a kx 250 2000 rolling chassis from ebay for ?300.
   I know this has been done before i would like to know if members want to see this one, also if anyone wants see the engine rebuild as it seems a few are apprehensive about spliting cases. i can go into as much detail as people require on the build and engine rebuild.
   heres some pics, i have found a horrible dent on the frame. I think i will source a new one unless anyone has some clever ideas

Hi,
limited knowledge of KX series or scramblers generally - looking for general advice about the KX500 - why did you get rid of your KX500 pls ?
What's the advantage of a 250 frame with the 500 motor - is there significant size difference ?

[jonny500]

the 500 was not changed much since 1989 althought it was sold untill 2002 in the U.K and 2004 in the U.S. i have to be carfull here because there are some serious fans of the k5 on here. the k5 i had was an 89 so was pretty bad to ride (through old age) and combined with the fact there was little devolopement of it between 89 and 2004. compared to a modern mx bike the k5 is a tough beast to handle. so the advantages, basically are 10 plus years of development. the kx 250 chassis it lighter narrower with supirior frame geometry and suspention for motocross which is the what this bike will be used for. thats not to say the kx500 is a bad bike because its not, from all account it is an exellent dessert bike too.
having said all that neither bike would be suitable for a bigginer

[jonny500]

not much progress today. managed to get a cr 500 pipe from ebay, its a  little rough but not alot else about, i will see if i can clean it up when it gets here. it will do to make the pipe mounts if nothing else. take a look http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=370437261879&ssPageName=STRK:MEWNX:IT

i made a template for the heads stay mount also

[jonny500]

i made some of the head stay today but ran out of time

[cutting torch]

Johnny, this thread is very close to my build. It's like deja-vu!

How does the fuel tank fit with the rear headstay that's on the K5? Mine had to go (the headstay).

torch

[jonny500]

its gota go, just not got round to it yet. did you post your build on here? i bet your engine wasn't as wrecked as mine though lol

[cutting torch]

Here is my thread:

http://www.kxriders.com/forums/index.php/topic,7388.0.html

torch

[jonny500]

yeah i watched it. i even found 1 of my posts on it. the reason its deja vous is cos i robbed some of your ideas lol, hope you didn't mind

[cutting torch]

Rob all the ideas you want! That's why I posted it.

torch

[jonny500]

finished the head stay, i will get it welded by someone else as my welding is poor (and thats being nice)