KX250 Street Smoker

Discussion in 'Some Assembly Required' started by nuggets, Jul 6, 2013.

  1. nuggets

    nuggets Fries with that?

    Joined:
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    I have decided to dual sport my KX250.

    It will make a nice <strike>practical long distance freeway mile eater</strike> hooligan noise machine. :D

    I got excited strapping on the headlight, and forgot to take any before pics. Anyway, you get the idea.
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    Slapped street wheels on. Cheapo-SUMO.
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    This bike has a powerjet carb, so it has a regulator/rectifier. I tap this for lighting power. Here is the connector. I'll tap the harness here for power at the reg/rec connector. I could have just bought a wiring harness, but it wouldn't fit as nicely as mine does, and it wouldn't just plug into the stock harness. I didn't save any money building my own though.
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    Front brake switch installed.
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    Here is the tusk light switch. I won't bother with the turn signals.
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    #1
  2. nuggets

    nuggets Fries with that?

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    The first problem was that the CDI is mounted on the head tube, so it interferes with the headlight mounting.

    I am mocking up some brackets to set the headlight farther forward here.
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    Mark, then cut. Thanks Vermont!
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    This gives enough clearance.
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    Cutting to final size.
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    Smooth
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    #2
  3. nuggets

    nuggets Fries with that?

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    Finished brackets
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    Dammit, the rear brake switch doesn't fit. I am omitting it for now until I get a low profile one.
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    Here is the start to the lighting wire harness. This plugs right into the stock harness. I started trying to build it using these blue green gel-filled telecom wire taps. That was a mistake.
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    This isn't working out. Motherbrother. :becca There is a fuse in there.
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    This is nice. I can plug right into the stock harness.
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    #3
  4. nuggets

    nuggets Fries with that?

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    The telecom half-taps suck for this, so I switched to mil-spec crimps. These things are great.
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    Wiring layout is messy, and it seems like I put the wires in and take them out a million times.
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    Here, I am nearly finished covering the harness. I used heat shrink tubing to cover all the wires.
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    Connecting to the taillight. Every connector got a preventative shot of dielectric grease.
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    I attached the headlight connector directly to the handlebar switch, and used bullet connectors to tie into the main harness.
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    #4
  5. nuggets

    nuggets Fries with that?

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    Today, I put black zip ties everywhere that gets sun. The black zip ties degrade less with UV exposure, and they look nicer.


    I also added this zip tie to keep the brake line from hooking on the headlight when the front suspension is compressed.
    [​IMG]

    Look at my tail. Yes my rear fender is tweaked. I'll be swapping over to VA plates this week.
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    Here she is, ready to go.
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    #5
  6. JonnyCash

    JonnyCash turd polisher

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    Be very careful! I think it will be so much fun that your head might explode.
    #6
  7. nuggets

    nuggets Fries with that?

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    You make an excellent point. :kboom


    I have tested it out, and everything works. Only issue is that the horn is completely drowned out by the engine noise. :rofl

    I'll have to come up with another solution, so I can pass inspection.

    I would like to put a quieter pipe on her.
    #7
  8. Ed_in_miami

    Ed_in_miami Cubicle Traveler

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    Very nice.
    I"m in the process of rebuilding a KX250F. I think i'll go the Street Way myself as well...! :clap
    #8
  9. nuggets

    nuggets Fries with that?

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    I think you will need a lighting coil though. Fortunately, the KX250 has a powerjet carb, so you can rob the 12V from there. It isn't much, but I only need barely legal.

    So, I have been riding this thing for a while, and it is just a hoot. :evil
    #9
  10. zig06

    zig06 Been here awhile

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    If you are looking for "barely legal" then consider hiding a 12v battery inside the air box and have your bike inspected like that. Then you can show that the lights and the horn works without starting the bike up. That's what I did when I got my '96 Suzuki RMX plated. :clap
    #10
  11. Ed_in_miami

    Ed_in_miami Cubicle Traveler

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    Good tip!
    #11
  12. dhallilama

    dhallilama Been here awhile

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    dig seeing this! i had a 90s YZ250 and a KX500 plated on the street years ago... such a blast. the YZ became my "practical" bike for a couple years... was actually great around town.
    the KX was almost the death of me more times than i could count.

    really miss that thing...
    #12
  13. KX50002

    KX50002 NooB, my ass

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    I have often dreamt of streeting my KX500, how is this done? Vermont tags??

    I'd love to SUMO the 500!!!
    #13
  14. nuggets

    nuggets Fries with that?

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    1999 or older KX500 can be vermont plated. No problem.
    #14
  15. KX50002

    KX50002 NooB, my ass

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    It's a 91!!!!!
    And I put a FMF Gold pipe on it so it really is a hooligan noise machine!!
    #15
  16. nuggets

    nuggets Fries with that?

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    You'll put your eye out with that :evil
    #16
  17. KX50002

    KX50002 NooB, my ass

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    I used to flat track it. One time my brother noticed I was getting wheelspin on the starts so he "adjusted" my rear tire pressure for me, but he didn't tell me... Next time out I looped the thing o the start!! Thanks BRO!!:clap:clap
    #17
  18. Canuman

    Canuman Crusty & Unobliging

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    +1 on the battery. Tusk has one for about $20 that's the size of a pack of playing cards. I used one on my recent KDX200 street-legal build. Tiny enough to mount about anywhere, and it can be rigged as a total-loss system if you wish to go super-simple. I upgraded the stator on the KDX, so I actually have an electrical system that could possibly get me out of the woods in the dark.

    Very cool build. Nah, you won't have any fun on that!
    #18
  19. orangebear

    orangebear Long timer

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    I was thinking of doing something like this but with out lights. As uk bike can be put on the road with no lights just a horn and Speedo and good tires.
    #19
  20. JerryH

    JerryH Banned

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    Nice. I love the idea of building a street legal supermoto out of a 2 stroke dirt bike, but it cannot be done in my state. It is very easy to make a 4 stroke dirt bike street legal, you don't even need turn signals or instruments. But you cannot do that with a 2 stroke because of the EPA. It can also be a real hassle getting insurance for a converted off road vehicle, because even though it has a street legal title, the VIN still shows it to be an off road vehicle.
    #20