07 KX250 Air fork conversion

JohnnyT_983
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JohnnyT_983
Edited Date/Time 11/2/2018 10:25am
just got this little guy on trade the other day and I'm looking to definitely keep this one. I'm not gonna go crazy with the build just clean it up and make it right for me.
Does anyone have any pro circuit clamps or applied clamps for the 05-07 KX250?
Also looking for a PC link to go along with it.
And last thing I'm trying to find a set of the aluminum frame guards from works connection.

I'll post more and more pics as I go, but this is it right now.

It needs a few things, fork seals, repacking, some jetting love but other than that it runs fantastic. Any mod suggestions would be fantastic as well.



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JohnnyT_983
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JohnnyT_983 7/12/2017 6:30am
7/12/2017 6:30am
I also just noticed that the 05 kx crank doesn't work in the 06-07 has anyone else ran across this?
And secondly has anyone used crankworks for crank rebuilds?
Markopolo400
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Markopolo400 7/12/2017 6:52am
7/12/2017 6:52am
05 and 06-07 cranks are different and do not swap.. The reason is the method of attachment for the primary drive gear on the right hand side.

05 the gear is held on with a cir clip, the 06-07 use a left handed thread bolt.

I had my 2006 crank rebuilt by Andrew Cooksey, he did a great job.
mattman631
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mattman631 7/12/2017 7:49am
7/12/2017 7:49am
I recommend Ken O'Connor Racing. Always done great work for me in the past
Hondas4Life3
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Hondas4Life3 7/12/2017 10:53am
7/12/2017 10:53am
You can convert kx250 to 06+ crank but you may need a new inner clutch cover. The kx65 also have the same crank update in 06 and I converted a 03 motor to use 06+ crank but I needed a few pieces and a new inner cover. The 06/07 design is much better and keeps the drive gear from vibrating/ moving

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sandman768
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sandman768 7/13/2017 10:26am
7/13/2017 10:26am
JohnnyT_983 wrote:
I also just noticed that the 05 kx crank doesn't work in the 06-07 has anyone else ran across this? And secondly has anyone used crankworks...
I also just noticed that the 05 kx crank doesn't work in the 06-07 has anyone else ran across this?
And secondly has anyone used crankworks for crank rebuilds?
I used crankworks to rebuild, balance crank with piston assy. Not cheap but professional, turn around time as qouted, no issues. Would use them again.
JohnnyT_983
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JohnnyT_983 7/15/2017 5:41am
7/15/2017 5:41am
Started pulling it apart last night to clean it and check over everything. Everything has been good so far just dirty, I always dread pulling the linkage off used bikes.... ugh I'll update Monday afternoon or so.
Should I stick with FMF stuff or go with Pro Cicuit on the exhaust? I've always had PC and tried the bills but.... idk maybe try DEP. What do you guys think?



mattyhamz2
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mattyhamz2 7/15/2017 10:41am
7/15/2017 10:41am
Nice pick up!! Love our 05. We run an FMF and it runs awesome. Don't forget to run race gas also! They love c12 at 40:1
JohnnyT_983
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JohnnyT_983 7/15/2017 1:24pm
7/15/2017 1:24pm
mattyhamz2 wrote:
Nice pick up!! Love our 05. We run an FMF and it runs awesome. Don't forget to run race gas also! They love c12 at 40:1
C12 is the only way to go.
JohnnyT_983
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JohnnyT_983 7/27/2018 8:08am
7/27/2018 8:08am
Been a hot minute since an update, but like I said it’s pocket change so it’s gonna take some time.
For a little bit I was out riding in the woods with the bike while I had the opportunity so it vaulted ny build but now I’m back on it
Ended up with a pc pipe and silencer, and got some
Wc frame guards from one of the vital members.






Then I had to pack everything up and move because we sold our house. Now we are in our new house and I was able to get a few more things done. I added a moose skid plate since it was really rocky where I was living in between houses and just wanted to ride.

I really just wanted some water pump protection.

Once I got my shop set up at the new house I tore it down and replaced steering stem bearings, fork seals, linkage bearings, wheel bearings, a couple spokes, the standard seat was replaced with an SDG, and I slapped on some tires, a cheap set of radiator hoses, painted my rad lovers black with high temp paint, and upgraded the plastics a little. I still have some work to do like OS front brake, stainless lines, and I’m really really wanting to find some PSF1 forks off the 13-14 Kx450f at a decent price.
All in all I think it looks good as a naked bike and it’s probably gonna match the 450 once I get graphics for it.
I’ll update when I can guys thanks for tuning in!







2
JohnnyT_983
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JohnnyT_983 7/27/2018 8:15am
7/27/2018 8:15am
Quick update I found a set of PSF1 for a good deal so I scooped em in a hurry.


Now I just need a set of clamps and I’ll be ready to go.
1
js171kx250build 7/28/2018 6:10am
7/28/2018 6:10am
I was wondering if you knew anything about how to find cases for a 2005 kx 250 I have literally tried everything I know
JohnnyT_983
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JohnnyT_983 7/28/2018 4:25pm
7/28/2018 4:25pm
js171kx250build wrote:
I was wondering if you knew anything about how to find cases for a 2005 kx 250 I have literally tried everything I know
They seem like they have fallen off to the nla program with kawasaki I can try to make a phone call on Tuesday for you to see maybe if I can locate a set.
You might have to check through eBay constantly and post an add in the Bazarr.
Other than that it’s gonna be hard to come by.
I honestly don’t know of the 06-07 cases will work due to the difference in the crank from the 05 model.
I don’t have that information unfortunately.
js171kx250build 7/28/2018 7:58pm
7/28/2018 7:58pm
Thanks I really appreciate it if you get the chance to call Kawasaki or able to give me a phone number to reach some one it's hard to find some one who knows something most of the time it's just some one answering a phone.... I noticed your only a couple hours from me in middle tn thanks for your time!!!
JohnnyT_983
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JohnnyT_983 7/29/2018 1:07pm
7/29/2018 1:07pm
js171kx250build wrote:
Thanks I really appreciate it if you get the chance to call Kawasaki or able to give me a phone number to reach some one it's...
Thanks I really appreciate it if you get the chance to call Kawasaki or able to give me a phone number to reach some one it's hard to find some one who knows something most of the time it's just some one answering a phone.... I noticed your only a couple hours from me in middle tn thanks for your time!!!
Heck yeah man shoot me text sometime
423-716-0198

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queen of spodes 7/29/2018 4:03pm
7/29/2018 4:03pm
OEM crank assembly still available from Kawasaki for 06-07 (and 08 europe). I bought one a few weeks ago.
JohnnyT_983
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JohnnyT_983 7/29/2018 7:18pm
7/29/2018 7:18pm
queen of spodes wrote:
OEM crank assembly still available from Kawasaki for 06-07 (and 08 europe). I bought one a few weeks ago.
Yeah the 06-08 crank
He’s looking for the cases. Do you think the 05 cases are the same or did they change it to accommodate the difference on the water pump shaft and that little crank deal with the pin vs reverse nut.
JohnnyT_983
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JohnnyT_983 8/1/2018 6:38pm
8/1/2018 6:38pm
The air forks came in today, now it’s about finding the right set of clamps. Good news is these came with the WC ez fill caps! Also got a really good deal on factory fatty and shorty from some old stock at a local dealer.
If anyone has a good set of 14 up Kx450f clamps that would be awesome!
Polishhammer 8/2/2018 5:00am
8/2/2018 5:00am
Nice build! Is there a specific triple clamp offset that works better for these kx250s?
JohnnyT_983
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JohnnyT_983 8/2/2018 7:39am
8/2/2018 7:39am
Polishhammer wrote:
Nice build! Is there a specific triple clamp offset that works better for these kx250s?
Not that I have necessarily tried, I had a set of 21mm clamps (I think) on an 05 that I did twin chambers on and it was a little too much.
I believe stock on these 250s were 25mm or close to it. I’m trying to find a set of stock 23.5mm clamps to try with these air forks.
JohnnyT_983
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JohnnyT_983 8/2/2018 7:41am
8/2/2018 7:41am
Also had the worlds gnarliest swing arm bolt, that has been at the machine shop for removal, it was so seized and rusted over that they were burning through drill bits and ended up having to cut it out

I’ll post a pic of the plug they put in with the new bolt as well.
DTR830
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DTR830 8/2/2018 6:54pm
8/2/2018 6:54pm
JohnnyT_983 wrote:
Quick update I found a set of PSF1 for a good deal so I scooped em in a hurry. [img]https://p.vitalmx.com/photos/forums/2018/07/27/277196/s1200_DE971AEA_1DBC_4F02_9BE6_CF11D28798DF.jpg[/img] Now I just need a set...
Quick update I found a set of PSF1 for a good deal so I scooped em in a hurry.


Now I just need a set of clamps and I’ll be ready to go.
I run these on my 96 kx250. 39psi zero complaints for me
queen of spodes 8/3/2018 6:04am
8/3/2018 6:04am
JohnnyT_983 wrote:
Not that I have necessarily tried, I had a set of 21mm clamps (I think) on an 05 that I did twin chambers on and it...
Not that I have necessarily tried, I had a set of 21mm clamps (I think) on an 05 that I did twin chambers on and it was a little too much.
I believe stock on these 250s were 25mm or close to it. I’m trying to find a set of stock 23.5mm clamps to try with these air forks.
When you say a little too much, what do you mean.. how did it affect handling exactly? Thinking about moving from 25mm to 21.5mm myself.
JohnnyT_983
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JohnnyT_983 8/3/2018 8:10am
8/3/2018 8:10am Edited Date/Time 8/3/2018 8:12am
queen of spodes wrote:
When you say a little too much, what do you mean.. how did it affect handling exactly? Thinking about moving from 25mm to 21.5mm myself.
I felt that the bike was unsettled and that it wanted to tuck at any twitch of the front wheel, I didn’t have the suspension really set up perfect and I think the PC link would have helped in that situation.
I honestly don’t mind the 25mm offset It feels unsettled at entry in corners but I think the 23.5 will settle that with 5mm up in the clamps.
m21racing
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m21racing 8/5/2018 11:22am
8/5/2018 11:22am
Thats a great build. Glad to see air forks on a 2t; specifically the psf 1.
JohnnyT_983
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JohnnyT_983 8/5/2018 2:53pm
8/5/2018 2:53pm
m21racing wrote:
Thats a great build. Glad to see air forks on a 2t; specifically the psf 1.
Thanks, I have been planning this for about a year now. I just have a feel that the lighter front end feel of the two stroke will benefit with the air fork vs being a negative deal like everyone hated on the four stroke .
queen of spodes 8/7/2018 2:59pm
8/7/2018 2:59pm Edited Date/Time 8/7/2018 2:59pm
JohnnyT_983 wrote:
I felt that the bike was unsettled and that it wanted to tuck at any twitch of the front wheel, I didn’t have the suspension really...
I felt that the bike was unsettled and that it wanted to tuck at any twitch of the front wheel, I didn’t have the suspension really set up perfect and I think the PC link would have helped in that situation.
I honestly don’t mind the 25mm offset It feels unsettled at entry in corners but I think the 23.5 will settle that with 5mm up in the clamps.
right on. I have the linkage, but bike is still in pieces with a build. Was close to ordering a set of triples with 21.5mm offset, but decided to hold off to see what the linkage and stock offset feels like.

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