How well do you like your KX250F/K5 conversion

[SHLEPY]

Im scared to death of my frame breaking with out holes through the rails thanks to my mistake of going to george at MPS but it may be a differnt animal for you it would be alot neater looking.

[sandblaster]

Yeah, there are good and bad points to doing like I want but I think the good outweighs the bad.
Thanks for your input.

[Motorrad]

In the mean time I am trying to figure out how I want to mount the engine mounts.
I know a lot of guys weld the mounts directly to the frame but it will make engine removal in this 250F frame all that much harder.
So, I am thinking about drilling through the square tubes and welding in aluminum tubing and running bolts all the way through the frame tubes.
Here is an example:



What do you think about that?
Or, do you have a better idea?

ahh.. the AF section.... the section of the site Im never in....   But since My presance was requested..

where on the frame tube would this end up?   middle?   

Take a picture with you pointing at the frame where the hoels would be... 

[cmotodad]

Not too revelent but I am doing my CRF250 to KX500 and in the section to raise the Y I put solid stock in then drilled and tapped for removable front mounts. Will post pix soon.

[Larry Wiechman]

 That's the best way to load that rail. Make the wall thickness of the tubes as thick as possible to prevent buckling under compression. Not a place to try and save weight. A M8-1.25 SHCS (Class 12.9) can generate about 6000 lb. clamping force.

[sandblaster]

Thanks Larry.
There are easier ways but I think it is the best so it's time to find some tubing...

[sandblaster]

Here is what that aluminum block is for (It's not welded just yet):



Now that I have that one made I will make all the other mounts and drill out the frame tubes for the aluminum tubing.
Looks like I will have to use 5/8 OD x 1/8" wall 6061.

[Larry Wiechman]

 Will the aluminum block capture the head mount so well that engine removal is impossible without removing the head nuts first?

[sandblaster]

I haven't actually tried it but I assume that the nuts will have to be removed before the engine can be removed.
I know it's not ideal but so far I can't find a better way of securing the head.
The last thing I want is broken frame rails..
Do you have a better idea?

[Larry Wiechman]

Do you have a better idea?

 I like the 2 plate system Kawasaki used for the head mount on the stock KX500. Upon disassembly, it's completly out of the way. Very forgiving of positional errors on assembly.

[sandblaster]

I agree.
The problem is I haven't seen any 250F conversions that had a good design for that due to the overall geometry of the frame, tank, ect.
Based on the designs I have seen I think that it why some have broken their frame rails.
If you have some good pics of a 250f conversion head stay mounting area I would be grateful.

[Larry Wiechman]

 Can you put 2 tubes (like lower mount) through the down tube and still get the tank to fit?

[sandblaster]

I'll take a look in the morning 

[SS109]

Instead of using a huge U shaped piece of aluminum on the frame to mount to the bracket how about just a simple wedge sort of like this?

[SHLEPY]

This is a 2006 kx 250f frame that was done by Jerry and the ims 3 gal tank fits with no problem hope this will help.

http://s1296.beta.photobucket.com/user/SHLEPY500/media/IMG_0783.jpg.html#/user/SHLEPY500/media/IMG_0786.jpg.html?&_suid=135493337071907457251697957659