KX Riders
Maintenance & Technical => KX250 / KX125 => Topic started by: elmo on April 03, 2011, 06:56:16 PM
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Guys, can this be re-conditioned? If i take it to the garage can they juice it up or something? It just seems soooo spongey and soft at the moment..
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Had this happen on a 92 125 and it turned out to be the seal in the bottom of the shock. If you take it to any bike shop they should be able to do it. I myself would take it to a suspension shop as you can have them set it to your weight and riding style
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Thanks buddy!! I'm going to take it across the road in a sec but none of the other garages want to take it :?
But visionMX gave me the number of Shock Tech just waiting on a call back from them! Also how the hell do you post pics on here?!?!? tried image hosting the using the url in between the img brackets but it dont work :-( new to the forum! But just as fragile and dumb as a new born lamb anyway so need all the help i can get!!
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hi,
I got quoted $150 cad plus material cost for the full rebuilt of my rear shock, need this done, too. As for putting pictures os here, just try photobucket.com load them up there and then just click on "direct link" under the picture and it copies it for you, then on kx riders click on the image button and paste the url in between the img brackets just like you already said!
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(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110401-00147.jpg)
Yes she is in my kitchen, yes my missis is still with me!
This is just the start of the body re-build!
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Next step clean and remove everything :-D
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110402-00151.jpg)
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remove rear wheel only to find shot bearings in wheel and swing arm, not to mention the rear wheel being from a KX85
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110402-00154.jpg)
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Rear shock removed and ready for re-furb!!
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110403-00160.jpg)
Swing arm has new bearings and the spacer bolts in the swing arm snapped, so had that drilled and re-tapped and got new bolts in there, Front ends all done and back together, fixed oil leak coming from drain plug, everything clean/greased and tightened!
E.T.C this weekend
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110403-00163.jpg)
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Guys does anyone know of any other shock's that will fit this bike? Like will a kx500 fit?? only i want another while i send mine for repairs.... Any ideas or anyone have one they wanna sell me?
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im pretty sure the 125 shock from that year will fit
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I have a '89 shock in my 91 KX250 but the clearance from the shock reservoir to the pipe is not the biggest!
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Cheers guys, might see if i can grab one of those 2 for now and in the mean time send my original one to shocktech.com let them rubuild it! i'll let you guys know how it goes! And thanks for the help!
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Anyone know if i'll get away with using 1989 KX500 rear shock for time being?
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OK guys few things ive learned....
1, KX125 and KX250 parts are the same as long as the year code is the same.
2, Air filters havnt changed much as i'm using a kx250 "97" in my "91"
3, kawasaki rear shocks are completely re-buildable
4, Kawasaki wakefield are very helpful and will rebuild ur shock for less than ?100
5, organise your tools as 20 minutes of every hour spent working is looking for tools your standing on!
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110406-00168.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110406-00170.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110406-00171.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110406-00173.jpg)
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Looking good, I just did the same with my 91 250 except mine had pieces missing all over. I found that out later on , too that the 125 parts fit, made it a bit easier. Still need to get my suspension built as well.
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:x New problem.... The tensioners in the swing arm SNAPPED Fuc@$%?$^?"^$"$%"&$%""%&^%&"
Tried getting them drilled out and the holes tapped... ALL of the drill bits have blunted or snapped even really high grade ones...
WTF am i going to do now?
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found a second hand one, ?80 bastard! Just gotta wait for both last parts to arrive now :-(
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Right guys Good News!! After all my hard work she looka a dream! Kicks first time everytime too!
This is how she looks now! Everything as tight as a new bike (except engine as i hadnt touched that)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110416-00198-1.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110416-00197.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110418-00212.jpg)
So i took her out for a track day to test out the new beauty! Low and behold Bad news always follows good..
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110424-00217.jpg)
First she wouldnt hit powervalves in 1st 2nd or 3rd... Then she soiled a spark plug....Still had a good few hours on her.... Lively, suprising hours as the powervalves sometimes kick in, could be anytime but always very late.... Making the back wheel very skittish :-D all funn aside i need to fix this before i take her out again... Any ideas anyone? anyone had this? I'm gonna try taking the valves out and cleaning them incase they carboned up... Other than that i'm lost... Do these bikes have cable operated powervavles?
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Ok so started tearing into it today, ordered new piston and top end gaskets along with a workshop manual... hopefully i'll just get away with a top end rebuild for now and it will sort out the missing power..
She's pretty black and got a nasty wobble back and forth
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110426-00224.jpg)
Powervalve's also look ok thats them nearly open, and the piston a little scratched
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110426-00231.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110426-00229.jpg)
Powervalve pulley?!?!?
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110426-00232.jpg)
But i have already cleaned the head ready to go, soon as my piston, rings and little end bearing get here (with the manual!)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110426-00233.jpg)
Now do i try an clean up all this black s**t? and the oily black s**t? and what do i clean it with?
Cheers guys
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Holy crap! :? what happened? what mixture were you running? once you get the new top end on make sure you mix at 40:1 and get the carb jetted! and it will never look like that again.
on my rm250 that runs 40:1 with amsoil interceptor, well i looked into the cylinder and it is SPOTLESS not even a single carbon black mark! which was unbelievable to me
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If the piston is wobbling in the barrel then i would look into having the cylinder re plated. It could be the bore is worn out. Looking at the top of the piston it looks like if your running 32:1 that you need to jet the bike badly as there is too much carbon on the top of that pistons
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Lol... I am still really new to this.. but I only bought this bike on the 31st of March!
Cheers for the heads up on the mix, i'll make sure I do that.. So I take it the black marks are not good?
The head and cylinder look in ok condition to me, but i'll know more once I take her top off. But i'm gonna wait till the manual gets here so I dont pull anything out wrong... specially that powervalve setup!
I was just using a standard 32:1 (156ml to 5 litre petrol)
Sorry guys whats jetting?
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No elmo, (LOL) the blackness should not be there.
you are going to have one hell of a scrubbing job to get everything clean! especially the power valves
and the exhaust port.
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oh yeah and 40:1 is 500ml to 20 liters of fuel.
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did you hear any piston slap when the bike was running?
my 89 kx250 had bad piston slap a LONG time ago.
here is an old video of it. at around 12 seconds you will hear the slapping
http://www.youtube.com/watch?v=XE9u6l7onmQ
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is that the noise where it sounds like its dying out?
if so then yes.... lol i thought that was just normal.... :roll: that was more than likely why i couldnt get her to idle!
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is that the noise where it sounds like its dying out?
its when the sound clearly changes at around 12 seconds
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wow i really have lots to learn lool, thanks guys so much... i know everyones prob pissing themselves reading this!!
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wow i really have lots to learn lool, thanks guys so much... i know everyones prob pissing themselves reading this!!
hahahaaha its perfectly ok to be ''slow'' at first. but it will get better
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:-/ I hope so... at least i'm eager! I have another few mates that recently started, they all bought bikes too... their bikes are in worse condition than this! They are both too scared to touch anything to do with it too.. I cant wait to bring this back out and show them what a real bike should feel like.. But from what you say i'm prob better off pulling the bottom end apart too an checking everything down there for wear too!
Also i take it jetting is done to the carb? What does that involve "specialist work"? And replating i understand what that is i'll just look into where i can get it done and prices.
Is it going to be nessacary? the piston can move in all directions about 1 to 2 mm.. i take it that is also not normal
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when i first got my bike i was afraid to change the water pump seal. well the way i did it was : make a clean and open work area , keep track of every bolt (all the bolts were the same but i didnt know at that time) , remember how things go back, and being very careful with the delicate parts . and TAKE YOUR SWEET TIME DOING IT. that cant be stressed enough , if you rush you are bound to lose something or break something.
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I run a 32:1 mix using yamalube-r. Once you get the bike running with a fresh piston, put a brand new plug in it and run it around a field and no higher than quarter throttle till its nice and hot then I'd check the plug color. If its black you need to change the pilot to a smaller pilot jet. if its white you need to go bigger but seeing as how theres a ton of ash on the top of that piston i would say your gonna downsize it. One thing I can tell you is that these kx250s are jetted rich from the factory and if no one has ever changed the jetting then it deffinatly needs to be changed.
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Thanks for all the help here guys and i'll keep you lot updated!
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Righ guys gonna sort out my jetting as you lot say its well out due to the carbon on the piston and the fact it fouls plugs pretty much all the time.
So i understand to do this i need to, decrease the size of my needle and adjust the air screw...
My question is, what size needle and how many turns on the air screw. Im only about 150m above sea level (so i'm basically a fish), in England.
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Hi,
could you write down the size of your main jet, pilot jet and what needle and on what clip it is from above? There could be something completely different in there from stock, or way off! I'm about the same elevation as you in British Columbia.
You could start with the needle on the 3rd clip from above and the air screw 1.5 turns out.
I run a FMF Gold Series pipe and a stock silencer, my needle (R1638J) is on the 2nd clip from above and the main jet is a 165, air screw 1.5 turns out, haven't checked the pilot jet, yet.
Stock at cheapcycleparts.com it says: Needle N85C, main jet 160, pilot jet ranges from 52 to 62.
Hope that helps...
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To give you an idea im running a 45 pilot 160 main at 750ft. Not sure on the needle. I would start by changing the pilot first though
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Thank you guys great help! i took the cylinder off today, Whats the best way to clean the cylinder btw guys?
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110428-00245.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110428-00249.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110428-00252-1.jpg)
And the bolts for the exhaust valve i didnt even realise wser bolts
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110428-00240.jpg)
Piston
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110428-00253.jpg)
And this is one of the reason the powervaves wernt opening!
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110428-00255.jpg)
And 1989kawasaki thanks for the heads up on bolt storage lol
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110428-00237.jpg)
i'll take the carb apart tomorrow and post the numbers on here...
Thanks again guys
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:-o i think the cyl needs replating , its hard too tell with all that black stuff there.
when you send the cylinder to a plater they will make the it look brand new
now to clean the power valves and that rod, i think you have to use oven cleaner and a scrubber.
A+ on the bolt storage , you will never lose a bolt that way :-)
estimated cost = $500 - 600 and that includes a new piston kit
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Right ok so the needle say's N85C and the clip is on the 3rd ring back and the air screw was 1 turn out!
ps... pilot says 55 on it!
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Take the drain plug out of the carburetor bowl and check what size the main jet is as well! But so far it looks stock.
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Main jet 160
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i would drop that pilot down quite a bit to about a 50. One thing that I can tell you is if the cylinder needs re-plating your going to want to send a brand new piston with it.
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cheers guys, i have a new piston.... so your saying send the new piston with the battered cylinder for replating? i imagine its so they can check the bore afterwards....
i'll order a new pilot jet later too.... cheers again guys
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Yes send it with the cylinder. They use it to check the measurement and clearances before and after the job. One thing I would do though is dont jet the bike till after you have the motor broke in. Once its broke in then start jetting the bike
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ok so found a new part to order.... and the main reason the KIPS wernt working!!
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110501-00259.jpg)
as you can see the pin has managed to snapp off and fall into the valve! Lucky i decided to pull the engine apart!
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http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=140529571969&ssPageName=ADME:X:RTQ:GB:1123
Snapped up!
cylinder sent off to aptec today too!
I'll let you guys know, but should be finished in 2 weeks!
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those valves you ordered look pretty good.
i am starting to get excited to see and hear the bike when its all complete :-D
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lol you'll get the power valves from that bike and I bought the front number plate from it :-D
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Sweet it's great how these bikes live on even through death!! Its wierd to think you'll be riding over there with parts from the same bike as mine :-D...
I'm finally getting excited now too....makes a change from all the frustration!! lol
Cylinder is on its way back tho!! No cracks just a straight re-plate! ?170!! But its been done by the industry leaders Aptec, Poeton! I just cant wait to torque her all back up! :-o
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and this is the job Aptec done :-D
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110512-00288.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110512-00287.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110512-00285.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110512-00289.jpg)
Wow i didnt realise it would come back like that!
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i was jaw dropped when i saw my cylinder after plating :-o :-o :-o :-o :-o
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Hi guys, just wondering... I was dry runing the assembley of the kips, I think I have them set correctly but the actual valves don't have the punch marks. How do I make sure they are in right?
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does this look right guys?
operating rod in
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110514-00299.jpg)
operating rod out
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110514-00298.jpg)
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what about the other side?
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otherside
in:
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110514-00302.jpg)
out:
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110514-00301.jpg)
Cheers guys
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id say it looks good
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:-D thank you guys... this is where i am now... Just need to torque her back up (dont have a torque wrench yet)!
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110514-00304.jpg)
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that cylinder looks very strange compared to the rest of the motor . but i cant wait to see it together :-o
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i'm planning to do the bottom end this winter so i think a new crankcase might be nereded
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a NEW one ? why? cant you just clean it like the cylinder was cleaned?
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they are discontinued but if you want new one nosparts.se has a NOS crank case set. part number 14001-5285 just email nosparts@telia.com
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i've seen a small crack in the left hand casing :-/ thats the main reason..
another quick question tho, the book says 25nm fore the cylinder head bolts, does that mean the 4 that hold the cylinder to the crankcase and the 9 that hold the head on?
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http://www.kxriders.com/forums/index.php/topic,9190.0.html (http://www.kxriders.com/forums/index.php/topic,9190.0.html) :wink:
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i've seen a small crack in the left hand casing :-/ thats the main reason..
another quick question tho, the book says 25nm fore the cylinder head bolts, does that mean the 4 that hold the cylinder to the crankcase and the 9 that hold the head on?
that nos place only has 1 left so you gotta act soon
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You can use the cases from 88-91 so there should be more available! Or you could weld/ jb weld the small crack and soda blast them, then it'll look brand new as well.
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You can use the cases from 88-91 so there should be more available! Or you could weld/ jb weld the small crack and soda blast them, then it'll look brand new as well.
all those cases have all different part numbers. new cases would be very nice.
jb is only a temporary fix. just sayin' 8-)
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I have a '89 engine in my '91 with a 91 head, the cases are all the same even though they have different numbers.
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Cheers guys thanks so much for the help..
Torque wrench i'll get tomorrow then fit her back and see if she goes BOOM or VRROOOM! :-)
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She went VRRROMM!
All back together nicely started with 5 pumps of the kickstart and one proper kick!
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110518-00309.jpg)
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110518-00310.jpg)
http://www.youtube.com/user/benji219?feature=mhee#p/a/u/0/M1DlrzfXJsk
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Looking good and sounds nice, too! Good job :-)
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looks and sounds awesome! that cylinder looks odd when comparing it to the color to the rest of the engine. but it looks good :-D and that chain needs to be de-rustified and tightened
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New chain on the way guys!!
heres hoping i solved the powerband problem!!
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have you ridden it yet??? :-o
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Nope that was the first time i started it! My friend dared me to film it as I said "If i film it the first time round something will go wrong"
To be fair i was right! If you notice i've forgotten to connect the kill switch! (dunce)
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Guys any idea why my clutch would be so tough to pull? It was before the re-build but wanna sort it out now the tops done.
http://www.youtube.com/watch?v=XnndAqewQJY
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You might have the harder clutch springs in there, my 88 is hard to pull and the 91 has the softer ones in there and it's way easier to pull.
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someone gave me an apico easy clutch... i'm gonna try this out now
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someone gave me an apico easy clutch... i'm gonna try this out now
is that one of those levers with multiple cable holes? or the cable with the inline linkage box?
i have a msr pro raptor waiting for me at my house ready to put on the bike and i will do a review soon on it.
its going to be a long night tonight , im heading back to toronto from vegas so its going to feel like its 3 hours earlier there ,
so i can put on my MSR tonight
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lol rather you than me buddy!
I've fitted this already it was quite quick actually! Fiddly but easy once i got it the right way round! first time I put it on it made it twice as hard..
(http://i1189.photobucket.com/albums/z433/ggore219/IMG-20110527-00318.jpg)
But now its on it does work but only about 30% difference...
Yh sorry 89 its an inline linkage, and yes the dog opened it for me today :-/
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So after another weekend at the track to break her in going real easy i dont think the p/v are kicking in again :-( so must be the guvnor... :-( pissed
But on the brigh side she has some Mental low end power now i could easily keep up with everyone on the track even tho i was only givin her 75% power.. heres a little video
(bear in mind this is england and there are some chavs on the course!)
http://www.youtube.com/watch?v=qSZqZdjXh_Q
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Hey El,
Well done, I looked at your other vids and the bike looks great. I'm sure you'll get the PV sorted abd she'll really scream.
And take it easy on the "Chavs" ... Your crew has plenty of entertainment while waiting for you to come in.
Actually, I think they were having as much fun as you were! well...almost :lol:
Take Care,
Tuck-O \o/
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I did wonder why everytime I went round those lazy bastards were still sitting in the same place!!
They may have been waiting for me to come in but twice that day i ran out of fuel on the track :? maybe cos i was doing like 20 laps at a time.... Yes my body is still aching!
But now she's broke in I can open her up, although when people came up beside me I had to push her a little more to make sure I stayed ahead as you see in the first part of the vid! Thats me and a CR trying to creep up on me... Lucky he wern't faster or i'd have had to back off!! Not next time though :-)
Next time i'll really scream her hoping the pv open up properly! if not back to the drawing board!
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Hey Guys! Long time no speak! I had a baby!!!!! Well I didn't the missis did.... Nyvian Gore born 4/08/11 8pm so bike has taken a months rest in the shed but tonight i start to pull her open again as i want to replace the operating rod for the PV before taking her out again on the 25th.. I'll update you guys soon.... P.s i know its far too early but i bought the boy an LT50 too which i think we can all agree is the best quad for a kid to learn on!
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Hey Guys! Long time no speak! I had a baby!!!!! Well I didn't the missis did.... Nyvian Gore born 4/08/11 8pm so bike has taken a months rest in the shed but tonight i start to pull her open again as i want to replace the operating rod for the PV before taking her out again on the 25th.. I'll update you guys soon.... P.s i know its far too early but i bought the boy an LT50 too which i think we can all agree is the best quad for a kid to learn on!
welcome back Elmo :-D congrats on the baby!! that must be exciting for you :-D
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Thanks dude!! Gonna start the bottom end rebuild after December so i'll keep you all posted!
"very exciting, very tiring, very rewarding"
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What do you reckon that the chances are of my powervalve issues are being caused by the actuator?
And does anyone know if i will have to pull the bottom end apart to get to it?
Also any ideas if the part is year specific or if a can use parts from other years?
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Never mind got a 1991 one for ?25.....!
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GUYS!! :-o :-o
Sorry but i'm putting back the exhaust advancer (actuator) but the pull arm has no spring in it, is that correct?? i can pull it out which makes the valves open but it does not return to the original position (closed) is that correct? according to the manual i put everything back correctly.... but the section in the clymer manual on this is very poor!
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thats fine
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Phew thanks 1989 may just be the end of my PV issues!!
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go out for a rip and see how it works :-D
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I'd love to but its 10pm here !
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Hey guys just wanted to let you know.... I fixed the PV issue :-D.... And f**k me does she move now... and sooo responsive! I have been unable to get her out of 3rd gear as i keep running out of room! The front wheel just jumps up and the back wheel dances everytime I touch the throttle! It turned out the Governor lever for the kips was wedged in the wrong part of the actuator! When i tried to un-do the bolt on the end of the governor lever it felt spring loaded and kept springing closed with alot of force! When I got it un-done, stripped and put back together, she moved open and closed effortlessly with no "spring" in the movement.. Now i only have a few more issues to solve before I can start on the cosmetics!
So in closing this post is to say thanks to everyone who helped, everyone who read and everyone who replied!