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Author Topic: My 1999 KX250 Build  (Read 2740 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
2017 KX250F/2004 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
2017 KX250F/2004 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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