Why, you ask, would anyone spend the time and effort to convert a motocross bike into
a woods racer, when so many other bikes can be had perfectly set up for woods
riding? The answer is simple: I don't know, but it sure is fun. Don't get me wrong, you
have to love tinkering with bikes and have a healthy amount of experience in the
saddle to know exactly what is needed to do a MX conversion. I did it twice. It's not easy
and certainly not something you want to do in a hurry. Fortunately for me, I found
outstanding deals on new 2003 and 2004 KX250's. Trust me, if you want to be first in
line and pay at or near retail price for the latest, greatest MX bike, it won't be
economical to turn it into a woods racer.
Here's what I did to both bikes, in order of priority:
a woods racer, when so many other bikes can be had perfectly set up for woods
riding? The answer is simple: I don't know, but it sure is fun. Don't get me wrong, you
have to love tinkering with bikes and have a healthy amount of experience in the
saddle to know exactly what is needed to do a MX conversion. I did it twice. It's not easy
and certainly not something you want to do in a hurry. Fortunately for me, I found
outstanding deals on new 2003 and 2004 KX250's. Trust me, if you want to be first in
line and pay at or near retail price for the latest, greatest MX bike, it won't be
economical to turn it into a woods racer.
Here's what I did to both bikes, in order of priority:
| Click on pictures for larger image |
Forks revalve $145
Shock revalve 150
Shims 50
Shipping to and from 45
Gun case (Walmart) 18
Fork Springs 80
Shock Spring 80
Total Cost $568
Shock revalve 150
Shims 50
Shipping to and from 45
Gun case (Walmart) 18
Fork Springs 80
Shock Spring 80
Total Cost $568
| A Perfect Match MX suspension and a cheap plastic gun case from Walmart. |
| After |
| Before |
Too Close for Comfort
Notice the grind job on the
pinch clamp bolt. Enduro
Engineering hand guard
bolts work even better.
Notice the grind job on the
pinch clamp bolt. Enduro
Engineering hand guard
bolts work even better.
No, it's not supposed to look
like that. This happened on the
very first ride.
like that. This happened on the
very first ride.
Not supposed to look like this,
either. IMS put a pair of pegs for
a late-'90's CR250 in a
package labeled for my '03
KX250 (IMS was kind enough
to exchange them for the
correct pegs). The correct pegs
fit just fine.
either. IMS put a pair of pegs for
a late-'90's CR250 in a
package labeled for my '03
KX250 (IMS was kind enough
to exchange them for the
correct pegs). The correct pegs
fit just fine.
One of the annoying things
about the right footpeg is that
the pin can't be removed
without taking off the clutch
cover.
about the right footpeg is that
the pin can't be removed
without taking off the clutch
cover.
| There you have it. This is why you need to get a really good deal on an MX bike in order for the woods conversion to make economical sense. |
Step 1: Revalve the suspension
Trust me, motocross valving in the
woods is bad. Very bad.
Sometimes you wonder if the
suspension is even there at all. I
sent mine to Drew Smith at W.E.R.
Racing. I wanted a specialist in
woods suspension tuning, and
Drew is the guy. For springs, I went
with .42's up front (.44 is stock)
and a 4.8 in the rear (5.2 is stock).
Step 2: Add flywheel weight
To keep from stalling and to
smooth out the power delivery a
bit, I added a Steahly Products 11
ounce flywheel weight. Installation
is simple - it actually replaces the
original flywheel bolt.
Trust me, motocross valving in the
woods is bad. Very bad.
Sometimes you wonder if the
suspension is even there at all. I
sent mine to Drew Smith at W.E.R.
Racing. I wanted a specialist in
woods suspension tuning, and
Drew is the guy. For springs, I went
with .42's up front (.44 is stock)
and a 4.8 in the rear (5.2 is stock).
Step 2: Add flywheel weight
To keep from stalling and to
smooth out the power delivery a
bit, I added a Steahly Products 11
ounce flywheel weight. Installation
is simple - it actually replaces the
original flywheel bolt.
Step 3: Get a larger gas tank
Two gallons just won't cut it for a
2-hour hare scramble, unless you
like stopping for gas (I don't).
When I bought the 2003 KX250,
IMS was the only larger-capacity
option (Clarke's tank later became
available - both tanks are just a bit
more than 3 gallons). The good
news is that the IMS tank fits very
nicely. The bad news is that if you
use an upper triple clamp that has
pinch bolts angled inward toward
the steering head (think KTM circa
2000-02), the bolts may make
contact with the IMS tank when the
handlebars are turned in all the
way. No good solution except to
get out the heat gun and mold the
tank to fit the clamp. To increase
clearance, use allen head bolts
like those that come with Enduro
Engineering hand guards. They're
a flatter, "pan head" style.
Two gallons just won't cut it for a
2-hour hare scramble, unless you
like stopping for gas (I don't).
When I bought the 2003 KX250,
IMS was the only larger-capacity
option (Clarke's tank later became
available - both tanks are just a bit
more than 3 gallons). The good
news is that the IMS tank fits very
nicely. The bad news is that if you
use an upper triple clamp that has
pinch bolts angled inward toward
the steering head (think KTM circa
2000-02), the bolts may make
contact with the IMS tank when the
handlebars are turned in all the
way. No good solution except to
get out the heat gun and mold the
tank to fit the clamp. To increase
clearance, use allen head bolts
like those that come with Enduro
Engineering hand guards. They're
a flatter, "pan head" style.
Step 5: O-ring Chain
Most MX bikes come with
standard chains, which won't last
very long in the nasty conditions
often experienced in hare
scrambles and enduros. I like the
RK X-ring chain.
Most MX bikes come with
standard chains, which won't last
very long in the nasty conditions
often experienced in hare
scrambles and enduros. I like the
RK X-ring chain.
Step 4: Get stronger footpegs.
The KX250 isn't designed for
crashing in rock gardens, which is
one of my specialties. I bought a
pair of IMS Pro series pegs, which
are much stronger.
The KX250 isn't designed for
crashing in rock gardens, which is
one of my specialties. I bought a
pair of IMS Pro series pegs, which
are much stronger.
Total Cost Summary*
Suspension $568
Flywheel Weight 100
Tank 200
O-ring Chain 50
Footpegs 90
Total $1,108
*in 2003 dollars
Suspension $568
Flywheel Weight 100
Tank 200
O-ring Chain 50
Footpegs 90
Total $1,108
*in 2003 dollars
But wait, there's more! Click <here> to see the other mods
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| KX250 Woods Conversion |