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nice, good work! Can't wait to hear how it works out in the end. You must be pretty handy with a tube bender? Are you keeping the front head stay, or chopping it off?

Most of the work is being done by my father in-law since he's retired. He actually bent the tubing using conduit bender and a torch and very knowledgeable hand. He was a welding and cutting instructor for the local college along with working in the sheet metal industry for a very long time. Mostly im a gopher... Go for this. Go for that. Tack here... And my favorite "move! let me do it" lol it's all in good fun and most people think we should have our own TV show.

I have plenty of room to keep the head stay so it'll stay for now. I used the head mounts from the rmz250 and will drill and sleeve the frame for the mount. That way the motor is easily removable.

Looks good. How did you position the engine and cut the swingarm bushings without the sprocket in place?

Tedh98 wrote:Looks good. How did you position the engine and cut the swingarm bushings without the sprocket in place?

That's why everything is just tacked in place for now. until I get my engine assembled for the final fit and burn everything in. Although I have eyeballed down the sprocket line and I'm almost 100% that it lines up but we will know next week for sure when the rest of my trans parts come in. Worst case I have to use some shims on the counter shaft to make it perfect.

Here are some pics of the silencer ended up using the kdx200 silencer and just modding it.





Heres the front pipe mount




And the rear head stay is stock one off the rmz250 just moved over for the kdx200

Here's the pics of the final welding on the frame time for posting and assembly. I will be powder coating the frame after I get back from our riding trip so for now it ll get a primer coat and black hi temp coat to keep the rust away.

What kind of bender did you use?

Tedh98 wrote:What kind of bender did you use?

Used a conduit bender and a torch to bend it. My buddy let me use his rogue bender but it only had a 1½ die and I couldn't make up the difference for it to work correctly.

Got the frame rattle canned to prevent rust until I can get it powder coated

It's looking great. Can't wait to see how it all turns out.

Ffryno13 wrote:Used a conduit bender and a torch to bend it.

Those are some impressive bends using just that equipment. I would keep an eye on those areas where the tubing is kinked/creased for any changes over time.

Tedh98 wrote:

Ffryno13 wrote:Used a conduit bender and a torch to bend it.

Those are some impressive bends using just that equipment. I would keep an eye on those areas where the tubing is kinked/creased for any changes over time.

Thank you. I'll definitely keep an eye on it we'll see how everything goes I may just buy the correct die and do it again depending on how well it works.

A little progress today from bare frame to what you see there. Still have the mods for the radiators to do, and get the wiring squared away. But everything seems to be falling into place nicely.

Oh, I did have to make some 3/16 spacers for the rads to clear the front head stay

The stock rmz coil and cdi brackets work perfect fot the kdx200 stuff.

I'm having a couple issues I'm not planning on running the lights right now so can I just unplug the rectifier And tape up the rear lights and front light leads?

Also my clutch doesn't seem to have much throw. And my lever seems to bottom out half way to the bars. Any suggestions?

She runs! Started up 5th kick. After I realized I needed to give a little throttle.





I did have to have the swing arm bushings milled down 1mm on each one. I don't like the bearing design for the rmz250 there are way too many things to go wrong. The stock rads do have to be modified and I'm a little worried they'll keep the motor "too cool" I have a few loose ends to tie up and some things to double check but all the hard stuff is done. I should be riding next weekend and I'll give a report.

Next I need to build a skid plate, get an oversized tank and pop singer dents out of my pipe but that can wait.

Shes 92% complete but I rode her around the yard to test my clutch and everything checked out. I still need to fab a skid plate and install the milled swing arm bushings. I'll work on the lights later

Nice woods weapon there for sure. Well done!


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Wow is that a nice build. Always loved the handling of RM's.

Nice man! Looks awesome! Glad someone is getting their bike done!

shoe757 wrote:Wow is that a nice build. Always loved the handling of RM's.

Thanks this is my first yellow bike but the handling felt nice playing in the yard

Tyl3r wrote:Nice man! Looks awesome! Glad someone is getting their bike done!

It's done as much as any of my projects are (never) im always doing something on them. Yours is way prettier though!