Maintenance & Technical > KX250 / KX125
90 KX250 rebuild
SOHC:
put most of my motor togeather only to find it didn't change past 3rd because I put a 4th gear from a 1992 witch needs to mate with 4 drive dogs not 3 :-P got a NOS one on the way now.
I rebuilt my brake calipers as they were jammed, the rear piston was all broken on the end so I machined it back in the lathe, its a bit shorter but its nice now.
Also I got rid of the small o ring seals in the top of the bore, they are the reason the pistons seize, and I have changed to DOT 4 brake fluid.
sandblaster:
--- Quote from: SOHC on September 18, 2015, 08:03:45 PM ---
Also I got rid of the small o ring seals in the top of the bore, they are the reason the pistons seize, and I have changed to DOT 4 brake fluid.
--- End quote ---
What I have found is that dirt get's pushed past the first dust seal and eventually becomes plugged up between the main seal and dust seal.
It creates a mud like concoction that can completely freeze up the piston.
Once disassembled and cleaned the piston should push in easily with your finger.
By removing the outer dust seal you should find that your brake performance will deteriorate much faster as dirt pushes past the main seal and contaminates the fluid.
If I were you I would get another outer seal... But then I really like to stop when I hit the brakes :lol:
SOHC:
I will give it a go with out those first seals, they were all shredded up and bits were poking out, I don't ride in dirt or mud so should be ok.
Both master cylinders have failed now, I think someone had put a mixture of DOT 4 and 5 in there
SOHC:
Got my new gear in the post today, and I got the wrong one, I wanted 4th but got top as is had a part number witch looked the same.
SOHC:
I ordered a 2nd hand 3rd gear to replace my damaged one and now I have the cases back together and the cylinder back on, I did a dummy assembly of the 1996 waterpump parts, they fit straight in, I just need to shorten the shaft a couple mm where the impeller bolts on.
This would be a good mod for anyone else who has a cracked or broken water pump drive in there 1990, PS you carn't use the later impeller, it doesn't sute the housing.
I got my swing arm repaired and that is all bolted into the frame with the motor, photos to come.
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