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Author Topic: My 1999 KX250 Build  (Read 6150 times)
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mjowen
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« Reply #30 on: September 14, 2018, 07:42:42 AM »

Did some of the plastics last night (front and rear fenders, number plate, side covers)



I also noticed i do have a small oil leak from the side cover...which i kind of figured as one of the prior owners had bent where it mates together. I'll run it as is for a bit and will then take the cover off and fix where it's leaking and put another new gasket on. Not a huge deal/concern.
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mjowen
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« Reply #31 on: September 18, 2018, 06:48:09 PM »

Got a couple more things done tonight, nothing special...

mounted the tank and bled the front/rear brakes. Noticed the front brake was all ghetto rigged up so i'll be ordering some new levers tonight (might as well get a clutch lever, too). As you can see in the pics...definitely not stock. Will order the mounting bolt/nut as well as the adjustment screw parts.



As for the tank...it's mostly mounted. Found out today after some searching that you can't buy the strap screw separate nor could i find the specs for it (or the tank button) so thank you very much to Umberto for measuring the bolts on your tank so i can get the parts needed at the hardware store tomorrow!

- Fluids came in yesterday
- Radiator shroud bumpers/dampers come in thursday or friday
- Levers and the oem adjustment/mount parts will be in friday or monday (ordering tonight)

I was really wanting to have all the parts in and kick it over friday or saturday but that might not happen until next week if the remaining parts dont come in.

End is in sight!!!
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mjowen
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« Reply #32 on: September 20, 2018, 03:43:39 PM »

Still waiting on parts to come in...but was able to get the tank/seat bolts done.

My tank was missing the screw/bolt for the strap and it was rigged up with some type of allen bolt for the seat button.
For some reason - you cannot buy these bolts separate from Kawi nor do they have part numbers for them so you can even see what sizes youre dealing with.

Umberto was nice enough to provide some measurements to me so i just put together a couple bolts/nuts/washers that would work. I mounted the seat earlier to check fitment and it'll work just fine. The strap also works just fine hooked onto the washer and the frame.

Used an m6x1 40 screw with a large head, a 1" washer, and two nuts on bottom (i was going to use a spacer so it looked nicer but they were out of the spacer that fit what i needed). For the bottom i used a m6x1 25 screw with the same head and an m6 washer and it fits perfect.





I also tracked down the small oil leak and it is in the inner clutch cover. When i first did this rebuild and split that cover i noticed there were two gaskets on there - i'm assuming the reason for that was the leak. Normally i'd try and grind it down and get everything to be perfect but i'm guessing it's warped so i'll just follow suit with the two gaskets and that'll be fine. Ordered another gasket in today so i'll take that cover off in the next few days to fix that leak.

Just have to get the parts in and should have more of an update Smiley

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umberto
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« Reply #33 on: September 20, 2018, 04:36:00 PM »

That worked out really well.  I'm still stunned that Kawasaki doesn't sell these parts separately.  I'm sure you aren't the first person to have that issue.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
umberto
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« Reply #34 on: September 20, 2018, 04:39:07 PM »


I have done a number of dirt bike flips off of Craigslist, and I've seen some really poor repairs, but this one has to make the hall of fame.  To quote Pcmg, "How many PBRs did it take to make that?"   grin
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
mjowen
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« Reply #35 on: September 20, 2018, 05:53:07 PM »

Yeah... The bolt that is holding the lever is just a fully threaded Bolt that barely fits and locks the break up when bleeding. The "adjustment screw" is just a rusted bolt. And if looks like they just used some jb weld or something to rig the lever.

New parts come in Monday lol
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mjowen
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« Reply #36 on: September 24, 2018, 02:10:45 PM »

Well...

ended up splitting the inner clutch cover last night, installed the new gasket today, and got the rest of the plastics on.

Going to oil the new air filter tonight, fill the crankcase to see if the new gasket fixed the leak, and wait for the new brake parts to come in. I've also gotta order a new water pump gasket since it tore when i removed it yesterday but the local kawi dealer is closed on mondays.

 Hoping to fire it up by this weekend Smiley
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mjowen
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« Reply #37 on: September 25, 2018, 11:22:28 AM »

Figured i'd post up a few pics of how it looks now that all the plastics and the seat are on...

No leaks from the inner clutch cover as of yet - poured the oil in yesterday around 530pm and nothing today. Hoping it'll be good to go for now...

Just waiting on the brake screw parts and the water pump gasket - then i'll fill it and hope for the best as i attempt to start it haha. Brake parts should be in today or tomorrow and the gasket should be in thursday or friday.

Sent some pics to a girlfriend of mine that is going to do the graphics for me as well so we'll see how those turn out. Since she's doing them for cost for me, i gave her creative freedom to kinda do what she wants based on the bike...trust her completely!

Lemme know what ya think so far















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umberto
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« Reply #38 on: September 25, 2018, 12:00:25 PM »

Man, that dude looks great!  The colors go really well together.  Of course now it will be really hard for you to get it dirty.   grin
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
mjowen
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« Reply #39 on: September 25, 2018, 12:46:25 PM »

thanks, man! I appreciate it...

I'm looking forward to seeing what my friend does with the graphics, too.

haha, i have no problem getting it dirty! She can be washed lol
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mjowen
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« Reply #40 on: September 25, 2018, 04:07:30 PM »

Alrighty!

The newest problem...the front master cylinder is definitely not for my 1999 KX250.

All of my front brake parts came in today...not even close to the right fit. I went through a few random year bikes for other models and it appears the cylinder is from an older Honda CR250 (1992-2006). Makes sense since the shock was also put together with random honda parts.

So! instead of getting a new master cylinder that will fit my bike - i'm just going to get another new lever and adjustment screw that matches the Honda master cylinder. Will be much cheaper and it'll still work.

Ugh. this thing is going to be the death of me.
« Last Edit: September 25, 2018, 04:16:40 PM by mjowen » Logged
umberto
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« Reply #41 on: September 25, 2018, 06:02:44 PM »

Alrighty!

The newest problem...the front master cylinder is definitely not for my 1999 KX250.

All of my front brake parts came in today...not even close to the right fit. I went through a few random year bikes for other models and it appears the cylinder is from an older Honda CR250 (1992-2006). Makes sense since the shock was also put together with random honda parts.

So! instead of getting a new master cylinder that will fit my bike - i'm just going to get another new lever and adjustment screw that matches the Honda master cylinder. Will be much cheaper and it'll still work.

Ugh. this thing is going to be the death of me.
A lot of guys have tried Honda master cylinders and say it is an improvement over the stock Kawasaki one.  You might be pleasantly surprised.
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Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525 - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144
mjowen
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« Reply #42 on: September 25, 2018, 06:11:19 PM »

Just need to make sure I know which one it's from lol...ive looked at the schematic a million times and there's a small difference between the one I have on the bike and the one in the pic

The one on the bike has a single prong where the brake line connects and the one in the diagram for oem parts has two prongs
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Foxx4Beaver
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« Reply #43 on: September 25, 2018, 06:32:10 PM »

Just need to make sure I know which one it's from lol...ive looked at the schematic a million times and there's a small difference between the one I have on the bike and the one in the pic

The one on the bike has a single prong where the brake line connects and the one in the diagram for oem parts has two prongs

I'll take a pic of mine and posted in a lil bit.
I'm runnin a 12 CRF450 master on my '00 250.
The stock Kawie brakes suck, but with the Honda master, they'll practically lock up if you breath on the lever...super touchy and strong.
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Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ
mjowen
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« Reply #44 on: September 25, 2018, 07:14:00 PM »

Greatly appreciated...

trying to view random google images and parts diagrams is giving me a headache. Cant seem to find out which cylinder this is.
might just give up and use the ghetto rigged lever lol
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