My 1999 KX250 Build

[mjowen]

Figured i'd post a few pics! My last post will be kind of a start to finish one as a recap...

Picked up the rims today with new tires, tubes, and spokes. Also got the swingarm dropped off for powder coat which i'll get back in a week or so.

Motor...all together (minus a couple bolts which i had to order due to them being wrong when i took it apart)



Rims/tires...new front and rear tires, new HD tubes, and new rear spokes







Hoping to have the forks back within 2 weeks (depends on the assembly)
Hoping to have the swingarm back within a week so i can put the new bearings in
Then will start the rebuild!

[mjowen]

well...my bad for the long absence...it took forever to get the swingarm back due to a personal issue the powdercoater had. oh well. Just got it back a few days ago.

Replaced the front and rear wheel bearings today
Forks are done and back
Shock is back (if i havent said that already)

Here are a couple pics of the frame and swingarm together. Frame is done in a 70% gloss gunmetal gray and the swingarm is done in a 50% gloss black.

I'll be doing the swingarm bearings tonight then hopefully going to begin putting things together tomorrow night. I have a best friends wedding which is taking up Thurs/Fri/Sat/Sun so i'm hoping to get the majority of it finished by sunday afternoon or monday since i took monday off.

Will post more pics as i start putting it together

[umberto]

That's going to be a very cool color combo.  Have you tried holding the plastic up to it to see how it looks with the green?  What color are you doing the subframe in?

[mjowen]

That's going to be a very cool color combo.  Have you tried holding the plastic up to it to see how it looks with the green?  What color are you doing the subframe in?

Did the subframe in the same gunmetal gray...havent held the plastics up yet because i havent gotten them. I dont think i'm going to go with the white/green plastics and am going to go with black. That way if i decide to do a green theme i can go with the graphics and always change. We'll see how it goes...kinda winging it at the moment haha. An ex gf of mine does the motox graphics for one of the shops close to me so she's going to do them for me at cost...thinking i'll send her a pic of the bike once its together and see what kind of ideas she has.

Just finished up the swingarm bearings...had some free time so got those done. Now might get the gas tank repair done - need to put some new inserts in as they're stripped out. I have all the parts already so going to hope the fix will solve the issue otherwise i'll just pick up a tank at some point.

End is somewhat in sight!!!

[mjowen]

Got the tank done last night...i may end up sanding the plastic bond a little but will decide that after i mount the plastics and check fitment.

One side of the tank was missing the insert entirely and the other side was stripped out and also had a bolt broken off inside it. I removed the stripped side and drilled a half inch mount. I roughed up the surface so the bond would hopefully adhere a bit better. I used my heat gun and softened the plastic then pressed a tee nut into the plastic, let it cool, then removed it. I used alcohol and cleaned up the surface then used plastic bond and pressed the tee nut into the hole. I used a bolt with some grease on the threads and end so the plastic bond wouldnt get into the tee nut. Once it dried a little i simply removed the bolt and let it finish drying.

Will it work? No idea...worst case scenario is it works for a brief time and then i end up getting a new tank down the road. Best case is that it works and only cost like 5 bucks.

[mjowen]

Finally got around to starting the rebuild...

got the frame/subframe/shock/motor done last night.

Planning to get a bit more done tonight so we'll see what happens! Supposed to meet a friend for drinks first which is why i'm only "planning" to get more done and it isnt guaranteed lol

[umberto]

Either way it will be a good night.   

[mjowen]

For sure...shes smokin hott and haven't seen her in a while lol

[mjowen]

Alright...got a little more progress done...she's starting to resemble a bike haha









I have most of the swingarm completed as well but when i was putting it together i realized i was missing a few oem parts so i ordered those in which should be here by end of week. Then i'll get the rear done. Also have fork guards and plastics ordered in which should be here at the same time.

So far completed:
- frame
- subframe
- shock mounted
- motor mounted
- radiators mounted
- hoses in
- harness routed
- front and rear wheel bearings done
- swingarm bearings done
- steering bearings done
- triple clamp mounted
- forks mounted
- front wheel mounted
- new front brake pads installed
- new grips done

What i dont have pictured is that i installed the carb and routed the throttle and cable

Next up:
- finish up the swingarm
- install the rear wheel
- install new rear brake pads
- install the gas tank
- install plastics
- install seat
- install exhaust
- mount the skid
- install new pegs (havent ordered them yet)

should be about it! Hoping to have it completed within a week or so - just depends on when i get the remainder of the parts.

[mjowen]

I've decided that i'll replace the carb vent hoses while i'm doing everything else...

so, going to pick up 10' tomorrow and will get that done as well...

I've got one shipment of some parts coming in tomorrow...another coming in monday...and the plastics in on tuesday. We'll see what happens for the rest!

I cant remember exactly how the harness routes and where two of the ground connections are and am also not positive on how the vent hoses are routed as they were all over the place when i got the bike - so, i'll read up on that tonight in the service manual and give it a shot tomorrow!

[umberto]

Looks like you are getting close.  You were smart to buy a service manual, they're a big help.

[sandblaster]

Looks like you are getting close.  You were smart to buy a service manual, they're a big help.

Yep... there are a lot of guys that have posted questions easily found in the Service Manual... Yes, me too 

[mjowen]

Got the new vent hoses done on the carb tonight...going to read up on the harness routing as well as the other cables tonight and will do those tomorrow (I did route the clutch cable tonight).

Ran into another issue though...i remembered the exhaust fitting weird when I took the bike apart so I did a quick test fit and it's not even close. Looked up the part number and the pipe that I have is for a 91-94 kx250.

Will clean it up and post it for sale on eBay for recover a little money (hopefully) and have ordered a new pipe for my bike as of tonight...

Hoping to have this completed by Friday next week!

[mjowen]

Got a bit more done on the bike last Friday but i had to take off to Chicago so i wasnt able to post any pics before i left...

- upper and lower fork guards on (havent mounted the guides yet)
- new c clip on the front sprocket
- new sprocket guide
- new clips for the vent hoses
- swingarm mounted
- rear tire mounted
- new rear pads installed
- new chain installed
- new pegs

Very impressed with how perfect the pegs matched my frame color choice - wasnt planned at all. I had the frame powder coated and then ordered the pegs months later.

My new plastics came in yesterday while i was out of town...new exhaust came in today...still waiting for a couple little parts coming in and then should have it all back together. Will also make sure all bolts are good just to double check.

Couple more clips are on the way along with new fuel lines. Then i'll fill her up with fluids and will nervously kick it over for the first time!

[mjowen]

Exhaust installed...



Now i'm just waiting on a few parts to come in to finish it all up.

Parts on order right now:
- carb clip for the throttle cable
- clamp for the vent hoses (including the one on the side near the front sprocket)
- bottom exhaust bracket/damper
- condenser clip/bracket
- new fuel tank vent hose
- fluids

once everything is received i'll finish up the clips and vent hose routes, oil and install the filter, get the plastics on, fill with fluids, and will attempt to start her up!