237 replies to this topic

[Jeezo TT Bronze Member]

The piece of rad hose on the kickstart looks stupid, but I havn't found another solution. it doesn't touch the frame, but it's close enough that it will rattle against it while riding.

[Jeezo TT Bronze Member]

Stay tuned tomorrow, I got my suspension back tonight all freshened up and comp reduced to a baseline woods setting.

Tomorrow will be mounting exhaust and final assembly for test ride, hopefully I won't hit any big snags, lol.

[Exbuhe TT Newbie]

Hey, just want to say, I've been watching this thread for a while, and I saw some of your original threads in the KTM section.
I am absolutely inspired by this project, and am in complete awe at everything you have done.
Maybe I'm being a bit dramatic, but really, thanks for posting this. I think it's opened me up a lot to the idea of modding my bike.
Thanks.

[englertracing TT Member]

Danny man no updates.... I want some pics!!
Please I don't mind the radiator hose on the kicker but...... Clear may not look stupid to you?

[Jeezo TT Bronze Member]

danny? my name's Joe, lol.

When I put it all together the pipe sat closer to the cylinder than I thought with the springs on, so I had to move my pipe mounts and take about an inch off the corner of the right radiator and cut the right lower radiator port off and weld it back on at a new angle.

All is well now though, suspension is back, but I'm waiting on 2 cup like washer's for the rear linkage, that, and a washer for the steering head.

engine pipe and frame fit all look great now, I'll post up some pics soon.

[jjhubbard15 TT Silver Member]

i dont want to imply that you didnt try this or think of it but cant you rock that kickstart forward a tooth?

[Jeezo TT Bronze Member]

jjhubbard15, on 26 April 2012 - 02:56 PM, said:

i dont want to imply that you didnt try this or think of it but cant you rock that kickstart forward a tooth?

It's WAY into the pipe if I do, they're pretty course splines.

[Jeezo TT Bronze Member]

Final details are getting tedious as hell.

I need to push in the bottom of the IMS gas tank about .25". Anyone know if there's a good way to do it or can I just heat it with a heat gun and push it in?


Need a longer throttle cable also. Going to either order a custom from motion pro or search for longer OEMs that will work.

[cwf340 TT Silver Member]

we have a local bike shop that can build cables, you may call around and see if any of your local bike shops can do the same.

Im not sure about the tank, what is it hitting on?

[Jeezo TT Bronze Member]

Thanks I'll call the local shops but they are terrible in Louisville.


tank is just barely hitting the head steady plates.

[cwf340 TT Silver Member]

I know what Im about to suggest would be a lot of work, but is there a way to repostion the engine lower or tilt it forward so that it clears the tank? tilting it forward would also solve the kick starter problem.

[Jeezo TT Bronze Member]

cwf340, on 13 May 2012 - 05:30 AM, said:

I know what Im about to suggest would be a lot of work, but is there a way to repostion the engine lower or tilt it forward so that it clears the tank? tilting it forward would also solve the kick starter problem.

It's already as far forward tilt as it can go. In order to go further I would have to do the entire swap over again on a larger frame, maybe a kx250 2t frame. The 250f frame will not allow it unless I cut and spliced in a new frame cradle much higher up close to the steering head.

I need to either cut away some of the right head steady bracket or push in the bottom of the tank a hair. I'll do some searching but I think pushing in the tank is supposed to be easy, iirc cr500 hybrids always have to mod the bottom of their tanks. anyone know?

[englertracing TT Member]

Well. I think you can use a heat gun and push on it but............
I would worry heating it will make it dry harder and more brittle.

[NemadjiMan TT Bronze Member]

englertracing, on 14 May 2012 - 09:33 AM, said:

Well. I think you can use a heat gun and push on it but............
I would worry heating it will make it dry harder and more brittle.

Gastanks are generally made of a thermoplastic, which implies that they can be remelted and reused without changing the properties of the material. It is highly unlikely that heating above the glass transition temperature (softening temp) and forming will change the basic properties of your gastank plastic, unless you actually burn it or something.

[englertracing TT Member]

NemadjiMan, on 15 May 2012 - 08:28 AM, said:

Gastanks are generally made of a thermoplastic, which implies that they can be remelted and reused without changing the properties of the material. It is highly unlikely that heating above the glass transition temperature (softening temp) and forming will change the basic properties of your gastank plastic, unless you actually burn it or something.

Well its probably pretty safe aslong as its not blackened..

[ubu TT Silver Member]

Headstays look like they could come down a bit.

[Jeezo TT Bronze Member]

I cut down the head steady plates and it looks like that will work, got a little more to take off.

FYI, I asked the banned500riders group about forming gas tanks, they said it's done all the time with no long term issues.


waiting on custom throttle cable from motion pro, +5"

[jar944 TT Silver Member]

It's riding season get that thing done