2005 kx200ac

[De250r]

I got piston gaskets bearings in the mail today. My exhaust should b here Monday so ill have to wait til after I get that to pull motor back out and rebuild


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[De250r]

I put the seat on this weekend. Waiting on parts still. Got my cb motor ready for the machine shop thou.


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[bufftester]

Love the idea of the motor mount, eliminates cutting and welding on the frame which improves it's re-usability for other projects. Being as AC bikes run a little hotter you might want to consider a heat shield between the head and tank. Have you thought about how you'll utilize the radiator shrouds? Since there is no radiator you could modify them to act as ram air ducts to channel cool air over the head. This is the build I've been wanting to do for ahile, glad to see someone go for it!

[De250r]

I was thinking about a shield over the head the other day. Look what I got It is gonna cut and weld perfictly. Gonna stainless tig weld it back together. And build a trim ring to go over the joint. The bend should line right back up good. I've looked at hundreds of pic of pipes to see what looks like it will cut and fit. It's nice to see it in my hands and I think it's gonna work nice.
Big box o parts


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[De250r]

Radiator shrouds will b air scoops and water bottle rack/ storage I think. I've got all the parts to put 2 bikes back together so I've got my work cut out for me. Gotta love it


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[scheckaet]

you don't necessarily need to cut that brand new pipe. You could get a used cheapo stock one,cut the part you need and weld it on top of your existing one. that's what I did. That way if you decide to go back, you just need to cut the extra part and you good to go

[De250r]

Too late already fired up the sawzall. I didn't have an existing pipe anyway. I looked at a bunch of stock pipes an most where crunched or they wanted too much. I wanted a nice looking pipe as well. This is gonna work out nicely. It will b about the same length as stock an it will curl around an have a nice radius too it. I'm gonna build a bumper for it. It stuck out a bit to much an was hitting on one fin. By trimming that little bit the pipe slid right back in nicely. Was thinking about building a heat sink of some sort to aid in cooling. Have it bolt on the head/jug some how.
I was looking at the vapor and it has a temp sensor that replaces the crush washer on your spark plug. Thought that was cool. Anyone ever use one on an air cooled? Last thing to figure out is what carb to run.


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[De250r]

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[De250r]

Zip tied it back together to see what it will look like.


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[zz3gmc]

Im really liking this build! What year engine are you using? 83-85 200? I thought about doing a similar build with a spare PE400 engine and a modern frame. Cool idea with the motor mounts!

[De250r]

It's an 84. Thanks I'm siked. Figure out how I'm gonna replate my pipe welds. Plug n plate from coswell looks like it will do the trick. $45 shipped its worth a shot. Look it up on YouTube/amazon. U can do copper nickel chrome gold silver plate with different kits.
Pics didn't load yesterday


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[rbates9]

In your pictures it looks like you have the body of the pipe zip tied tight to the down tube of the frame. You might want to space that out an inch or so before you weld it back together if it is tight to the frame.

[De250r]

Ya there will b plenty of space all around. Prob use doubled up cardboard to space it. Good eyes. We don't want any rattles


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[rbates9]

Where about are you in the back woods of VT? I might have to stop by and take this thing for a spin when your done.

[De250r]

I live in the northeast kingdom. Near st johnsbury. We ride every other weekend mostly. More the marrier.


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[zz3gmc]

Hows the countershaft sprocket alignment? Did you have to space the motor over to one side or the other? Did the swingarm need trimming?

[De250r]

No lines right up straight. Kawi must use the same geometry for there motors since 1970. Had to trim the case to except the linkage ears on each side when I put the motor in the kx500 frame. It slid right in this after that. Hmmm so a kx500 motor would slide in too. Scary.


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[zz3gmc]

I built a hybrid using a 04 KX250 chassis and a 02 KX500 engine. It was pretty straight forward. Everything lined up also. Had to trim the swingarm and move the front motor mount. I also centered the headstay to line up with the head. Thats about it as far as anything major goes.
Heres a pic from our Daytona Bikeweek trip last March.

[De250r]

Pretty sweet bike. Must b a hand full. I like hybrids/hotrods.


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[zz3gmc]

Although you do have to treat it with some respect it is actually very easy to ride. I race enduros on mine and with some throttle and clutch control it will go as fast as anything in the tight stuff. It has a tremendous amount of torque so Im able to ride it a gear high which makes for a smooth ride. Its tamed down some with a optional thick head gasket, 14oz flywheel weight, and a FMF Gnarly/Q silencer combo. I have another 04 chassis sitting in the corner and my wife wants me to build her one! She rides mine easily and starts it easily also! Cant wait to see your hybrid, I like the air cooled engine in a modern frame idea!