Maintenance & Technical > KX250 / KX125

My 1999 KX250 Build

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mjowen:
Well - no pics at the moment but i'll get them up eventually...

motor is done. Just have to go get the top end from the shop which i had resleeved.

Shock has been dropped off to have a rebuild done (full rebuild for 130 including parts)

Frame is at the powder coater which i'll get back eventually...

Next up:
- fork rebuild with bushings, seals, fluid
- order the rest of the parts
- start putting her back together!

mjowen:
Sorry for the late post...

took quite a while to get that frame back for some reason. Oh well...it's back and now i can continue!

Here is how the frame turned out:


I've got the front and rear tires mounted
new radiators and hoses in the garage
new filter in the garage
all new oem bolts
shock has been rebuilt
chain and sprocket kit in the garage

Now just waiting for the forks to be done...one of the forks was missing a valve assembly so ordered that today and will rebuild the forks. I also have a few new bearings ordered which i'm waiting for (front and rear wheel bearings as well as the steering stem bearings)

Next up:
- start putting everything back together
- rebuild the carb or at least clean it
- fix the gas tank mounts (one spins free and one is missing entirely)
- order the new plastics
- new graphics kit

mjowen:
Just a quick update...

- carb cleaning done
- fork assembly ordered: apparently they're now discontinued so had to track one down rather than ordering it through the shop

I'll post a quick photo later tonight of the motor and rims/tires.

I've also shot a message out to a shop to get the swingarm coated - its really not in great shape as you can see in prior photos. So, we'll see what happens there!

umberto:
Sounds like you are making progress.  Definitely more pics please.   :-D

mjowen:
haha, i will for sure...i've been slacking in the pic department lately. I got a new puppy about 6 weeks ago and he's been taking up quite a bit of my time as well!

Here are the issues i've run into so far:
- most of the bolts are all different sizes and head types so had to get all new
- missing some clamps here and there but wont know exactly until i start the rebuild
- missing a fork valve assembly on one of the fork tubes
- rear wheel spokes were shot so needed a new spoke kit on the rim before the tire could be installed
- wheel bearings were shot both front and rear as well as the swingarm bearings
- gas tank mounts for the plastics are stripped: one is missing entirely and one has a broken bolt inside and spins freely - will fix that as well
- sight glass is cracked but ordered a new one and will replace when i do a fluid change next

anticipated issues coming up:
- i ordered the valve assembly from rockymountainatvmc, they said one was in stock but i have a feeling they're going to tell me they dont have it as its been discontinued so will have to track one down
- i expect to have to replace the brake lines as everything else has been shot
- i believe the pipe that was on the bike is the wrong one as there were some fitment issues. I havent looked into it but will tonight or tomorrow: might sell the current and pick up a stocker if so.
- i expect to have some issues with the wiring and kill switch: it looks alllllll spliced up and crappy. so, we'll see.

I think that's it for now but i'm sure i'm missing something lol. Lots of issues here and there but overall has been a smooth...

I'll post some pics tonight or tomorrow...need to pick up the rims either today or tomorrow :)

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