Maintenance & Technical > KX250 / KX125
90 KX250 rebuild
SOHC:
I thought I would start this topic so I am not posting silly questions all over the place and you can see what I am dealing with.
Anyway I got this 1990 250 that was in bad shape the guy sed it was all there with the new parts and it just needed putting together witch was a lie, the new parts didn't fit as they were for a jet ski, the motor had sucked in lots of water and sand and the new piston kit looked like it had 4000 hours on it, all the bearings in the motor gearbox were rusted and warn out, I had to replace 2 and 3rd gear and the out put shaft, radiators were bent and crushed, expatiation chamber and exhaust were bent, rusty and crushed, all suspension bearings were rusty and the lower shock bearings had long since warn through the bearing into the link it self, front forks had corroded so badly they might snap. I lost alot of the before photos but I have a couple.
I will post up the pictures of my work
SOHC:
This is the photos the seller took of it in his shed and before I washed and sanded it.
SOHC:
This is the best I could get the expansion chamber. I hope to find another one one day.
I gas welded a peace of aluminum CB antenna mast I bent to make a new tail pipe, I don't have a TIG welder and its hard as hell to gas weld aluminum, I also replaced the exhaust pipe inbtween the muffler and expansion chamber as someone had used brazing rods and silver solder to try and repair rust and cracks
I had the link welded up and re bored as it must have worn though the bearing into the link at some stage and someone had bored it right out and hammered in a different bearing and packed it out with washers, yuck.
Swing arm needs the wheel adjusters welded up and re drilled and tapped as both threads are bad as some monkey had tried to re drill one and messed it up
SOHC:
I tried to fix my old radiators but after I twisted one straight I think I cracked it, but I saw thees China radiators witch were very cheep and they don't look half bad so I grabbed a set witch was lucky as it was the last set he had, and anything is better than my old ones.
SOHC:
This is where I got stuck and ran into trouble, my front forks were corroded to the point they may snap, I got a pair of 1992 forks but they didn't fit my 1990 axle or yokes. So I got a pair of 1997 yokes witch then didn't fit my bearings in the steering head so I pressed out the steel spindle in the bottom yoke from a pair of 1992 KDX250 yokes witch is the same as my 1990 spindle and sweated that into the 1997 bottom yoke, I also had to use a KDX top yoke is it takes the bigger forks but still had the same spindle bore as the 1990.
Now if all goes to plan I just need to make 2 sleeves to put over the ends of the front axle and easyflow them on so they can fit the bigger axle clamp.
I didn't paint the frame, I did polish the fork legs.
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