More progress!!!!
OK here goes.....My compulsive nature has never really let me mix and match parts to make a "Frankenstein" bike but there is a first time for everything.
Here is the bike so far......the front fender is for an 05 KX250 (KX500 front plate did not need trimming)
The front brake master cylinder and steel braided brake line are from an 01 CR250 (for CR style routing
The fork guards used are for an 05-06 RMZ 450 (for the brake line clamp mount)
The Suzuki fork guards were used for a few reasons.....
For one, they are larger than the KX500 fork guards, and with the CR style routing I needed the mount for the brake line clamp. Here is a picture of the KX500 fork guard next to the already mounted RM fork gaurds....another good point to mention is that the Acerbis RM fork guards are made from very dense, thick plastic and are rigid enough that the top fork guard guide is not necessary.
The RM fork guards are almost a plug and play upgrade. In order to make them work I had to do a little trimming and spacing......not a whole lot of work and effort was needed to make them work though.
The front holes line up close enough to bolt right up however the side bolt hole ends up to far back. To fix this I had to add some 1/8 inch little spacers to the front mounts and the side bolt hole lines up perfect.
Here is where the spacers were added (picture taken looking down the fork tube behind the fork guard)
Believe it or not I pulled the spacers from the old KX500 fork guards....hahaha!!! The old fork gaurds come with some metal inserts which I pulled out to use as spacers......The picture below shows the empy holes from which they came.....
Next came some trimming.....I had to use a dremmel to cut away where the "old" brake line mount came in contact with the "new" brake side fork gaurd
The KX500 brake line clamp was just a bit tight to go on so I also had to do some "very slight" trimming at the brake line mount on the new fork guard......but not very much!!
Although both fork guards needed the 1/8 inch spacing to mount up, all the minor trimming that took place was only to the brake side fork guard. I myself like the way it all came out.
The insanity continues on year 3 of project "I was only gonna clean the air filter"!!
On a side note: The Renthal Fat Bar is now obviously mounted along with the ASV levers and GPR damper...My brand new FMF Desert Gnarly and Turbine Core II silencer showed up in the mail as well.....
