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300 hours of hard work
I managed to find a 1994 Kawasaki KX250 without an engine and bought a '96 Husaberg 500-engine.
The '94 KX is basically the same bike as the '98 KX which means the chassis
still is up to date.
Just to put in a new engine should be a reasonable amount of work I thought,
but as usual there is more work than you think.
I estimate that I have put about 300 hours of hard work in the project.
Many of the changes had not to do with the switch from 2- to 4-stroke,
but with the fact that the Husaberg has the kickstarter and the outgoing sprocket
on the opposite sides compared to the Kawasaki.
So what did I have to do?
The frameClick on the photos to view a larger image
The "wishbone" in front of the engine, I moved it downwards because it collided with the exhaust pipes.
I also had to move the radiators upwards for the same reason.
The left frame tube collided with the kickstarter...
I also had to move the brackets for the chain rollers to the right side.
Swingarm
The Husaberg engine is wider where it meets the swingarm so I decided that the swingarm had to be widened there.I put a chain guide on the right hand side,
and welded on a stop for the new, left hand side brake caliper.
Other changes
I had to make a new gasoline tank in aluminium, the stock tank collided with the cylinder head and carburetor.
Jonas Melin, a friend of mine, welded it for me.
He has TIG welded the rest of the bike as well, helped me with good ideas
and given me a hand when I couldn't manage on my own.
The exhaust system is built from Husaberg and automobile parts.
I had to make new hardened steel bushings at the rear of the engine:
the Kawasaki swing axle is 1mm bigger and the Husaberg bushings were to hard to drill.