Author Topic: KX 250 1989 Rebuild in progress  (Read 7196 times)

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Offline golash

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KX 250 1989 Rebuild in progress
« on: December 18, 2011, 12:37:51 AM »
Hi All

After 25 years without a motorcycle I picked up a tired old KX. This winters project is a complete restore. The
bike is dissembled down to the frame. I plan to spray paint the frame. The engine is my big concern. The first step
will be to take a look at the piston and bore. I`ll clean all the carbon off the exhaust power valve etc. I`m not
a expert in engine rebuilding so I need some advice. Since the engine is out. Should I have the cases opened and
have a look at the transmission. I`d have to have this done by a professional. I would be in trouble if I attempted it.
That will be expensive I`m certain.
I`d appreciate any advice you may have for this newbie re-builder.

Thanks and regards Barry


http://i391.photobucket.com/albums/oo351/bgolash/KX%20250/DSCF0000001.jpg

Offline 1989kawasaki

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Re: KX 250 1989 Rebuild in progress
« Reply #1 on: December 18, 2011, 08:03:52 AM »
Yeah you should have the engine disassembled and cleaned very well and closely examine all of the gears
and check to see if the gear dogs and slots are rounded and all of the other parts too.
and if you need a total engine overhaul  like a full tranny , crank rebuild , cyl plating , piston, clutch baskets and plates,
gaskets, and if you get it done by a shop then you are looking at around $2200 parts included++ .. well at least thats how much i paid for my engine and thats not including the other costs like the plastics , paint, shifters and kick start, bearings , fork seals and so on.

if you are looking for a part that is not available (as most parts are not from kawasaki) let me know what it is and ill try to look for it for you.

i do have some decent parts i am willing to sell. i have a decent clutch basket, hub and plate. and 20 new oem spokes

 :-D
bikes

1977 RD400
1989 CR250
1988 CR500
1978 Z50
2009 Harley super glide custom

Offline golash

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Re: KX 250 1989 Rebuild in progress
« Reply #2 on: December 18, 2011, 08:56:10 AM »
Hi 1989 kawasaki

You have been a big help. I think I`ll have the tranny looked over. I`d prefer to deal with all the issues
at one time. And the time is now since the engine is out of the frame. I`ve had good luck so far with OEM
parts. How many of the parts are no longer stocked.
Its been a long time since I road a dirt bike. If I still find it fun in a year. I`ll probably sell this bike and upgrade to a newer
Kawasaki that still has OEM parts available.

Offline 1989kawasaki

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Re: KX 250 1989 Rebuild in progress
« Reply #3 on: December 18, 2011, 11:20:01 AM »
Hi 1989 kawasaki

You have been a big help. I think I`ll have the tranny looked over. I`d prefer to deal with all the issues
at one time. And the time is now since the engine is out of the frame. I`ve had good luck so far with OEM
parts. How many of the parts are no longer stocked.
Its been a long time since I road a dirt bike. If I still find it fun in a year. I`ll probably sell this bike and upgrade to a newer
Kawasaki that still has OEM parts available.

ok cool,

really if you think about it you dont really NEED to buy alot of oem, there is aftermarket like UFO, weisco, EBC and lots more.
and there is always ebay for NOS and used stuff.

and again if there is any NLA (no longer avail.) stuff you cant find , just let me know
i bought many VERY expensive NLA parts and i had no problem finding them

best of luck with the resto  :-D
bikes

1977 RD400
1989 CR250
1988 CR500
1978 Z50
2009 Harley super glide custom

Offline golash

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Re: KX 250 1989 Rebuild in progress
« Reply #4 on: December 22, 2011, 02:12:48 PM »
Hi

I have the engine out and took it to the mechanic. He mentioned that it needed a new piston and honed the bore. I`m now working on
the frame. I was using some stripper but that didn`t seem to touch the factory paint. So I sanded the frame. After 5 hours of sanding and
cleaning I have some brown rustoleum primer on the frame. I found some custom paint online in a aerosol can but was to cheap to spend $30 on the
paint. I found some paint at Autozone for $7.00 that comes close to a match. The frame after 22 years was very beat up. The primer is hiding
the imperfections in the frame nicely. Today I finish painted the frame...looks better.

http://i391.photobucket.com/albums/oo351/bgolash/DSCF00012.jpg
http://i391.photobucket.com/albums/oo351/bgolash/KX%20250/DSCF00043.jpg?t=1324679377
« Last Edit: December 26, 2011, 05:42:39 AM by golash »

Offline golash

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Re: KX 250 1989 Rebuild in progress
« Reply #5 on: December 26, 2011, 05:55:34 AM »
HI all

I`m moving along on the KX. The swing arm ended up being more work then I thought. I was going to buff and polish the swing arm.
After some work. I came to the conclusion a high polish wasn`t the answer. I used my woodworking dual action sander and did
all the flat surfaces with 220 grit. Then I hand sanded with 320. So the end result is a brushed look. I then applied a few coats of
wax to help retard the oxidation process.
I`m keeping an excel spreadsheet of the running total. I have  $1012.00 into the bike.
New Parts: Sprockets, chain, all plastic, piston, head gasket kit, OEM shift lever, stainless steel bolt kit -ebay.

http://i391.photobucket.com/albums/oo351/bgolash/KX%20250/DSCF0007.jpg
« Last Edit: December 27, 2011, 01:44:41 PM by golash »

Offline golash

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Re: KX 250 1989 Rebuild in progress-Engine Work
« Reply #6 on: December 27, 2011, 01:40:43 PM »
Hi
The engine is beginning its rebirth. At the moment I`m waiting for the piston kit. In the meantime I`m cleaning the various parts.
I purchased some small diameter brass wire brushes for my dremel. With the dremel and some Mothers polishing paste the engine is
looking much better. After I`m done with each part I wax it. Here is a link to the brass brushes. http://www.amazon.com/gp/product/B003NBYSJC/ref=oh_o00_s00_i00_details

http://i391.photobucket.com/albums/oo351/bgolash/KX%20250/DSCF0004.jpg

Offline jonny500

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Re: KX 250 1989 Rebuild in progress
« Reply #7 on: December 28, 2011, 05:01:49 AM »
i noticed on the cylinder there is something stamped on it directly above the power valve link cover. this is not stock i dont think. hmm have we got somthing special here  :|

Offline golash

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Saved $24.00 by making my own chain guide mounting bracket.
« Reply #8 on: December 30, 2011, 02:45:14 PM »
Hi
I got tired of spending money on the 1989 KX 250. So I made the chain guide mounting
bracket.


http://i391.photobucket.com/albums/oo351/bgolash/KX%20250/chainglide.jpg?t=1325302670

Offline weymouth399

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Re: KX 250 1989 Rebuild in progress
« Reply #9 on: December 30, 2011, 02:53:22 PM »
Very nice.

Bob W
93 KX500 ice bike for sale
00 KX 500 ice/dirt
04 KDX220 dirt
04 Kx 500 ice bike
08 KLX 450 on/off
72CT90x2 for sale
76LB80Chappy
86FJ1200
89FJ1200

Offline golash

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Another DIY part for the chain guide. Is it correct.
« Reply #10 on: January 05, 2012, 12:18:49 PM »
Hi all

I had a piece of nylon kicking around and decided to make a new chain guide. I ran the part on my
1969 Bridgeport milling machine. I only had the old part as a reference to copy. I`m not quite certain
if its correct. Please check my work.

Best Wishes, Barry

http://i391.photobucket.com/albums/oo351/bgolash/KX%20250/BottomChain.jpg

Offline Friar-Tuck

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Re: KX 250 1989 Rebuild in progress
« Reply #11 on: January 05, 2012, 03:35:06 PM »
Hey Go,
 Looking great so far!  I certainly wished I had gotten some  training as a machinist and a few Machines to make all the cool stuff you guys make...I am Jealous...
   Keep up the good work, That old girl will be singing along sweetly come spring..
  Tuck\o/
"The Truth Has No Agenda"    Jefferson
"With Malice toward none."     Lincoln

Offline tribaltalon

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Re: KX 250 1989 Rebuild in progress
« Reply #12 on: January 05, 2012, 04:12:14 PM »
looks good! always a satisfaction to make parts yourself instead of forking out money!

Offline golash

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Re: KX 250 1989 Rebuild in progress
« Reply #13 on: January 06, 2012, 12:55:27 PM »
Hi
Thanks for the positive comments. I am a hobbyist machinist with no training just books.
I am a cabinetmaker by trade. Over the years I`ve built a few woodworking machines.
I got tired of going to machinists with prints for each custom part. Now I can do it.
This a motorcycle forum but if any one is interested I have a machinery page at my website.
http://www.woodsolutions.com/diy-cnc.htm   This one is a 3 axis CNC. No plans or kits just my design
http://www.woodsolutions.com/planer-sander.htm This is a sander and planer. No plans..just my design.


Best Wishes Barry

Offline royceymon@hotmail.co.uk

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Re: Saved $24.00 by making my own chain guide mounting bracket.
« Reply #14 on: January 08, 2012, 06:29:54 AM »
Hi
I got tired of spending money on the 1989 KX 250. So I made the chain guide mounting
bracket.


http://i391.photobucket.com/albums/oo351/bgolash/KX%20250/chainglide.jpg?t=1325302670
nice bracket!!!