KX Riders
Maintenance & Technical => KX250 / KX125 => Topic started by: SOHC on August 18, 2015, 05:29:36 PM
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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
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1299_zps2roynvse.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1299_zps2roynvse.jpg.html)
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This is the photos the seller took of it in his shed and before I washed and sanded it.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/377424450_zpsdhr7zjl5.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/377424450_zpsdhr7zjl5.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/379553831_zpsnqurujk3.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/379553831_zpsnqurujk3.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/377424853_zps9oub72gr.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/377424853_zps9oub72gr.jpg.html)
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This is the best I could get the expansion chamber. I hope to find another one one day.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1448_zpspgdts8mt.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1448_zpspgdts8mt.jpg.html)
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
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1445_zps062izulo.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1445_zps062izulo.jpg.html)
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.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1450_zpszuleto1t.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1450_zpszuleto1t.jpg.html)
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
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1444_zps0yqtsmjw.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1444_zps0yqtsmjw.jpg.html)
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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.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1447_zps64oz3mka.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1447_zps64oz3mka.jpg.html)
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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.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1443_zps535fgejo.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1443_zps535fgejo.jpg.html)
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Had to have some welding done on the inner clutch cover and on the engine case where the clutch cable mounts as it was broken off, then I beet blasted the engine cases and fitted all new bearings, seals etc,
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1449_zpsdmljtb0c.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1449_zpsdmljtb0c.jpg.html)
I had to find a new crankshaft as someone had put in KDX250 flywheels witch were junk anyway, I now have a proper crank but it needs a new rod kit.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1446_zpsootsfvii.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1446_zpsootsfvii.jpg.html)
Thats about it for now, my cylinder is off being replated and I am looking for that clutch leaver that goes into the case. I would say alot of the damage on this bike was done form water blasting and steam cleaning.
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Awesome build so-far, SOHC. The forks mission sounded like a royal pain in the @$$. Love to see the progress.
Ed
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I ended up getting forks from the UK, there must have been something dodgy going on with the gold forks in 1990 because mine were corroded and cracking apart like yours. I am curious how the chinese radiators fit up as I am yet to buy any for mine. Keep up the good work and the updates as I know I haven't updated my build thread in ages.
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The radiators did need tweaking as the mounts for the guards and the mounts to the frame were off, I can see where one pin hole in a weld has been penned over at the factory.
I think with the forks its the anodizing when it gets a chip water can get under it and get trapped and it fizzes away, I polished it all off some blue forks and I will just hit them with the silicon spray, they did have a couple spots that I had to grind out.
I saw a Yamaha yz 250 that had the most rotten forks ever, they had swelled up to about 25% more of there orinagle size.
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My forks were nearly that bad. The aluminium has swollen and flaked like cast iron does. I'll post a picture tomorrow to show you.
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I have seen many of the earlier USD forks with the flaking.
I just parted out a 1990 and the Uppers are nice.
But, they are silver, not gold.
Must be a USA thing.
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Must be a US market thing with the silver forks.
You don't happen to have the clutch leaver at the gearbox end and a clutch basket would you from the 90 you parted out Sandblaster?
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Here's one of my fork legs.
(http://i763.photobucket.com/albums/xx276/aussiedrzguy/1990%20KX250%20Restoration/006_zps721433ec.jpg)
I bought a new Mitaka clutch basket off ebay.
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You don't happen to have the clutch leaver at the gearbox end and a clutch basket would you from the 90 you parted out Sandblaster?
I don't know what all I have just yet.
Here's a link to what all I have for it right now
There is some more stuff but I'm working on it.
http://stores.ebay.com/OEM-CYCLE/_i.html?_nkw=kx250+1990&submit=Search&_sid=680025 (http://stores.ebay.com/OEM-CYCLE/_i.html?_nkw=kx250+1990&submit=Search&_sid=680025)
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That fork leg looks like my old one LukeG , watch out it may go very deep into the leg itself, I will look into one of those new clutch baskets, might save a lot of work as I was going to weld up my old one.
I try to get stuff from ebay but a lot of the sellers won't ship to Newzealand
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I try to get stuff from ebay but a lot of the sellers won't ship to Newzealand
That's because they are cry babies :cry:
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I try to get stuff from ebay but a lot of the sellers won't ship to Newzealand
That's because they are cry babies :cry:
We are just a s**t stain on the map
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Shipping is more then the part :oops:
http://www.ebay.com/itm/KX250-KAWASAKI-1990-KX250-90-LOT-A-CLUTCH-ARM-LEVER-/371416971032?fits=Year%3A1990|Model%3AKX250&vxp=mtr&hash=item567a2d3718#shpCntId (http://www.ebay.com/itm/KX250-KAWASAKI-1990-KX250-90-LOT-A-CLUTCH-ARM-LEVER-/371416971032?fits=Year%3A1990|Model%3AKX250&vxp=mtr&hash=item567a2d3718#shpCntId)
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I did notice that 90-04 kx500 uses the same part.
I wonder if you might find one in NZ..
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I did notice that 90-04 kx500 uses the same part.
I wonder if you might find one in NZ..
A KX 500 is a very rare thing here and worth a lot of money.
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Are they available from a dealer new?
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Are they available from a dealer new?
No way, they pop up 2nd hand tho
http://www.trademe.co.nz/motors/motorbikes/motorbikes/dirt-bikes/auction-924096240.htm
http://www.trademe.co.nz/motors/motorbikes/motorbikes/dirt-bikes/auction-924082067.htm
I would like to get one but it would have to be a wreck I fix up.
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I sent my cylinder off to be replated but they had an exchange cylinder I went for as it was a bit cheaper to do the exchange system and would save me quite alot of money as mine was cracked and need welding and the exhaust spring hook was also broken. I still need to pay them and they will send it to me.
Also pressed in the Pivot Works kit bottom linkage bearings with some sockets and threaded rod and packed them with grease.
I am totally broke now and don't think I can get any more new parts.
I still need a
Rod kit and get it pressed in.
Head gasket,
Inner clutch cover gasket,
Clutch leaver, gearbox end.
Possible clutch basket and plates.
Swingarm bearing kit.
Brake caliper seal kit.
Chain and sprockets.
Air filter.
Radiator hoses kit.
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Someone snapped off the wheel adjuster then drilled a hole next to it, need to get it welded
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1453_zpsuiq08zgl.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1453_zpsuiq08zgl.jpg.html)
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I think I will use this clutch basket for a wile, its warn but I will give it a file and a set of plates
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1459_zpszhax8epm.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1459_zpszhax8epm.jpg.html)
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Could someone tell me if this ok, carbon fiber reads, they look ok but if I hold them upto the light there are clear spots
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1455_zpsasfftden.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1455_zpsasfftden.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1454_zpsprhi2btj.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1454_zpsprhi2btj.jpg.html)
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What if you flip the reed petals over?
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I was more worried about those pinholes, they arn't holes just clear spots in the resin but I was worried it was the reed wearing out?
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it had this strange spacer witch I think is home made
It was probably made for extra clearance for a flywheel weight.
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How would a flywheel wight change the power?
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How would a flywheel wight change the power?
As far as I understand it, it is made to smooth out the power delivery of the engine, making a little less wild and also a little less easy to stall. Good for technical riding like rock gardens or single track woods riding etc.
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I can see someone has removed something from the rotor with the magnets, it must have had a steel disk riveted to it at some stage.
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One question are the front engine plates steel or aluminum for my bike? they were missing but I got some KDX ones and they are steel.
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I got my replated exchange cylinder, its the wrong one, :-(
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I got this power-valve governor rod on ebay, its brand new :)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1479_zpslbelp6lj.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1479_zpslbelp6lj.jpg.html)
Also I got a new set of steering bearings and put my front end on, and rear shock and s**t is going back together.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1474_zpsg0nszh3a.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1474_zpsg0nszh3a.jpg.html)
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Looking great!
Keep the progress moving forward 8-)
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Next plan is to get the rod kit and crank done then I can put the cases to together and with any luck my cylinder will turn up.
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You're build has made me want to show mine, same bike. We can share notes.
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You're build has made me want to show mine, same bike. We can share notes.
Yes it is quit satisfying rebuilding a bike, I have just had alot of trouble with 2nd hand parts, the seller says its good but when I get it its junk, like the clutch basket I just got, not only is it rooted its for an 1987
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Dose a 162 main jet and a 55 pilot jet sound like an ok place to start? I am in the south pacific.
The bike came with 2 old pistons and both had score marks on the front and back, needle was on the 2nd to bottom clip, but the guy had been putting new pistons in the bike with out removing the head and there was baked on carbon on the cylinder walls round all the ports.
I am going to have some stickers made for the bike from an 80s KX, I will get them resized to fit.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/k00987_zpsiocd4r9f.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/k00987_zpsiocd4r9f.jpg.html)
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(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1506_zpsvhotvuie.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1506_zpsvhotvuie.jpg.html)
I just printed one out to test.
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Got a good 2nd hand crank with a rooted hotrod kit in it but I have a new Japanese prox.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1504_zpsqpf7zse4.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1504_zpsqpf7zse4.jpg.html)
this is old junk from the motor.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1503_zpsszfybq3v.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1503_zpsszfybq3v.jpg.html)
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Will a head gasket from a 1992 work? it measures about 0.7 of a mm bigger uncompressed than the old compressed 1990 gasket
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1508_zps2sinuirq.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1508_zps2sinuirq.jpg.html)
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I also had to make a new locator pin for the head, a peace of #8 wire was the same size
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1510_zpstyiv8qkr.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1510_zpstyiv8qkr.jpg.html)
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What way round dose the water pump seal go? non spring side to the water?
also here is my water pump conversion, I plan to fit a late model water pump as the old ones are hard to find, it looks like it will work with a little work.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1514_zpsbg4yqxpp.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1514_zpsbg4yqxpp.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1513_zpsonhuw6pc.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1513_zpsonhuw6pc.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1512_zps91jqbghw.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1512_zps91jqbghw.jpg.html)
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After a few emails I got a good clutch arm witch wasn't rusty.
And some sand blasting and cleaning of parts
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1511_zpsjfcyg8p6.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1511_zpsjfcyg8p6.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1507_zps5pft9mqg.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1507_zps5pft9mqg.jpg.html)
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got a swing arm bearing kit, all the other bearings are Pivot Works but this is a made in Taiwan kit
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1505_zpsttpsyeet.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1505_zpsttpsyeet.jpg.html)
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Sandblaster has got me a clutch basket witch is on its way from the US to me now, still need some clutch plates and some gaskets as the 2 gasket kits I got don't have every gasket for some reason.
I will get the rod kit pressed in at some stage, I use to do it my self in my younger days when I had full rain on a motorcycle shops workshop. I can put the cases together soon, I hope nothing binds up.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/maxresdefault_zpsoanpkzaf.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/maxresdefault_zpsoanpkzaf.jpg.html)
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Got my repaired and replated cylinder back, they did a good job apart from I spotted one flake of chrome in one of the ports that I had to remove as it was going to brake off and cause trobble.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1519_zpsqzmnmlau.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1519_zpsqzmnmlau.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1520_zpszyvfttzc.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1520_zpszyvfttzc.jpg.html)
they recommend 5 mins running at idol then 25% more for another 5 mins, then 30 mins at light throttle, then cool down and re torque the head then give it another 30 mins light throttle.
My crank is getting pressed as we speak to.
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Looking forward to seeing the results.
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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.
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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.
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:
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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
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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.
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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.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1512_zps91jqbghw.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1512_zps91jqbghw.jpg.html)
I got my swing arm repaired and that is all bolted into the frame with the motor, photos to come.
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I had my swing arm drilled and a steel insert screwed into the damaged hole someone had failed at drilling and tapping 3 times, and a hellicoil put in the other side.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1529_zpsre3vea0i.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1529_zpsre3vea0i.jpg.html)
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Also fitted the swing arm and links, there is zero play now, it had about 30mm before, installed the motor, need to make new front engine mounts and weld a bracket to the frame for the exhaust.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1524_zpsk0s0q9pc.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1524_zpsk0s0q9pc.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1525_zpseut1krzt.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1525_zpseut1krzt.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1526_zps3rgbymyj.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1526_zps3rgbymyj.jpg.html)
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Rebuilt both front and rear master cylinders, the rear one the cerclip was very rusty and broke into 3 parts, I have no brake fluid to test them.
I just need to find a clutch plate kit, I welded all my steel plates together to make a tool to hold the clutch hub.
Need a intake boot rubber thing.
chain and sprockets.
Air filter.
Weld on exhaust bracket and fix both flat tiers. then fun times begins, hopeful fun in riding and not finding why it won't go :evil:
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Looks good SOHC! That motor looks like you can eat off it. Cant wait to see the complete bike. 8-)
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Thank you, the whole engine has been beed blasted and wire brushed, I hope it will stay like that for a wile.
I made a new bronze bush for the kick start idol gear and was about to put the clutch side of the motor together but found the primary drive gear on the clutch basket was very worn, I am now in the process of changing that gear witch is held on by a aluminum plate witch is riveted on.
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Thank you, the whole engine has been beed blasted and wire brushed, I hope it will stay like that for a wile.
I made a new bronze bush for the kick start idol gear and was about to put the clutch side of the motor together but found the primary drive gear on the clutch basket was very worn, I am now in the process of changing that gear witch is held on by a aluminum plate witch is riveted on.
Yeah... I sold it to him, somehow I missed it, completely my fault :x
Working on it to make it right..
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Thank you, the whole engine has been beed blasted and wire brushed, I hope it will stay like that for a wile.
I made a new bronze bush for the kick start idol gear and was about to put the clutch side of the motor together but found the primary drive gear on the clutch basket was very worn, I am now in the process of changing that gear witch is held on by a aluminum plate witch is riveted on.
Yeah... I sold it to him, somehow I missed it, completely my fault :x
Working on it to make it right..
I have nealy fixed it, my old basket had a good gear, I drilled out all the rivits on both clutches now and was going to rivet if I can find rivets or do it like they say here. https://www.diymotofix.com/blog/how-to-repair-your-clutch-basket-dampers-for-less-than-30
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Drilled out the rivets on my bad clutch basket to remove its good drive gear, you have to center punch the rivets in the dead center and start off with a small drill and work to a bigger one as I broke the old basket trying to drive out a rivet, lucky it was the junk one.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1550_zpsosjaqhy7.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1550_zpsosjaqhy7.jpg.html)
The mint basket had a worn gear but its too good to walk away from, so I will swap them over and ether rivet or thread and bolt the cover back on.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1553_zpstwxypmxd.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1553_zpstwxypmxd.jpg.html)
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Sandblaster honored the clutch basket witch I am very grateful, I have tapped the rivet holes 1/4" UNF as they are a fraction too much oversize for M6 blots and I will just bolt the cover on to the cushdrive.
Also got a peace of aluminum plate to make the front engine mounts, I used the KDX mounts to trace around to get the right shape.
I have splashed out and ordered a new Boyesen RAD valve.
Will get some photos soon
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Not sure how I missed this thread for so long. Very awesome work!. Some of the parts you started with were ROUGH....... Ill be watching.
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(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1578_zpsnemndud8.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1578_zpsnemndud8.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1579_zpsqle63cd6.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1579_zpsqle63cd6.jpg.html)
All together, I used locktite and I hammered the ends of the bolts so they will never come out.
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Cut them out this morning, total cost to make 0$
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1577_zpsl6aevgzt.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1577_zpsl6aevgzt.jpg.html)
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(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1581_zpstum8ax17.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1581_zpstum8ax17.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1580_zpsqzqs3h1u.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1580_zpsqzqs3h1u.jpg.html)
Made this from the old clutch plates, I like to use this over my rattle gun.
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This is off a 1993 but it was cheep so I grabbed it, but I think it will fit.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/415225739_zpsj38mtyws.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/415225739_zpsj38mtyws.jpg.html)
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Very nice work on that basket.
Can't wait to see the finished product.
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Nice work SOHC!
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Sounds like the same deal I got. Don't think ANY of the previous owners ever took the wheels off, and if they did, it was at a shop where they didn't care to clean anything, just slap on a new tyre on the messy wheel and back on the dirty bike to go ride it. I applied plenty of grease on the inside of the rim around the spoke nipples to try waterproof the rim.
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Sounds like the same deal I got. Don't think ANY of the previous owners ever took the wheels off, and if they did, it was at a shop where they didn't care to clean anything, just slap on a new tyre on the messy wheel and back on the dirty bike to go ride it. I applied plenty of grease on the inside of the rim around the spoke nipples to try waterproof the rim.
LOL yes people ride them in the sea or water blast the hell out of the bike and drive all the crap into the bearings and seals.
I could see the dates of manufacture on the tires and they were over 12 years old so that would be around when the bike last the the tires off I would say
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LOL yes people ride them in the sea or water blast the hell out of the bike and drive all the crap into the bearings and seals.
I could see the dates of manufacture on the tires and they were over 12 years old so that would be around when the bike last the the tires off I would say
:-o :-o :-o
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(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1592_zps2n9mbhp0.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1592_zps2n9mbhp0.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1590_zpsrdoej2fb.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1590_zpsrdoej2fb.jpg.html)
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(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1589_zpssnecuxlr.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1589_zpssnecuxlr.jpg.html)
Wating for my radiator grommets to turn up and need to find someone to fit my seat cover.
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That is really coming along nicely...
Good job! 8-)
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Old reed cage and reeds and intake boot were shot so got a Boyesen reed block.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1594_zps7xla7z90.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1594_zps7xla7z90.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1595_zpsb6mbj5em.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1595_zpsb6mbj5em.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1596_zpsqrqgbgqp.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1596_zpsqrqgbgqp.jpg.html)
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I am unsure witch is left and right for the upper radiator hoses, one is different, at a gess I would say the shorter one goes to the tall left hand radiator?
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1597_zpsbhqndftd.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1597_zpsbhqndftd.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1593_zpswauh3h5o.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1593_zpswauh3h5o.jpg.html)
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I don't know whats up with my rear brake, peddle goes right to the stop and nothing much happens, it has a rebuilt caliper and a rebuilt master cylinder with a new kit in it, there are no leaks and the bore looked good, I can't get any pressure.
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Did you use a vacuum tool to draw the fluid or did you gravity bleed?
Sometimes even with a vacuum tool they can be a pain.
If you have someone that can help, you have them pump the tool while you keep the reservoir full and you also actuate the brake system.
Sometimes nothing else will work...
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Did you use a vacuum tool to draw the fluid or did you gravity bleed?
Sometimes even with a vacuum tool they can be a pain.
If you have someone that can help, you have them pump the tool while you keep the reservoir full and you also actuate the brake system.
Sometimes nothing else will work...
I haven't used a vacuum pump thing, I got the piston in the caliper to pump out then push it back a few times till all the air was gone,
I have tried holding the caliper at different angles wile bleeding it, I wonder if there is air in the master cylinder that won't come out?
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Sandblaster was right, there was still air in the rear brakes, Used the syringe to pull the fluid through and now it has a good peddle.
Rugged expansion chamber and plastics let the bike down look wise. I will post some photos soon.
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A handy tool someone suggested for me was a one way valve for bleeding brakes. Stops air going back into the line after you have pumped and makes it easy if you are trying to do it by yourself.
Looking forward to seeing this one done!
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I am unsure witch is left and right for the upper radiator hoses, one is different, at a gess I would say the shorter one goes to the tall left hand radiator?
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1597_zpsbhqndftd.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1597_zpsbhqndftd.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1593_zpswauh3h5o.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1593_zpswauh3h5o.jpg.html)
Both my radiator hoses look more like the one on your left side, the one with the "slight" bend. They must have changed the design a bit in the aftermarket hoses.
There are a couple pics of the hose setup in my build thread.
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I am unsure witch is left and right for the upper radiator hoses, one is different, at a gess I would say the shorter one goes to the tall left hand radiator?
Both my radiator hoses look more like the one on your left side, the one with the "slight" bend. They must have changed the design a bit in the aftermarket hoses.
There are a couple pics of the hose setup in my build thread.
Yes my old hoses both had the 90 bends in them, I put the 90 degree one to the left as it had another bend in the top to match up with the top radiator pipe.
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My chain guide was chewed up so badly I threw it away, I got this one witch is ok, I had to make a new nylon block for the bottom part
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1600_zpsniwfycel.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1600_zpsniwfycel.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1599_zpskj4xt9sz.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1599_zpskj4xt9sz.jpg.html)
Dented pipe
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1598_zps7gnrgan2.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1598_zps7gnrgan2.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1601_zpspdmdiprf.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1601_zpspdmdiprf.jpg.html)
Shed it full of junk as the house is getting work done on it, I would like to get plastics kit and a DG pipe and I have a Suzuki RM front numberbord on it witch sucks.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1602_zps8kgavjwp.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1602_zps8kgavjwp.jpg.html)
I just need a clutch kit and an air filter + chain and sprockets.
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all that nice work has kind of disappeared into those s**tty plastics :-(
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Have the plastics a good sand and a buff and they are OK, seat cover is getting fitted.
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Here is how to restore your plastics.
https://www.youtube.com/watch?v=n5JLhBEcROc&feature=youtu.be (https://www.youtube.com/watch?v=n5JLhBEcROc&feature=youtu.be)
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Here is how to restore your plastics.
https://www.youtube.com/watch?v=n5JLhBEcROc&feature=youtu.be (https://www.youtube.com/watch?v=n5JLhBEcROc&feature=youtu.be)
Cool thank you,
I went and got a buffing wheel for the drill and tried this, it works pretty well, the problem is the wite bend marks ans deep scratches.
The petrol tank is genuine Kawasaki and was easy to polish but the UFO plastics are hard and horable and gooey to sand and buff.
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Seat cover has been fitted, its from a 1993 so didn't line up 100%
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1639_zps8l5vsxql.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1639_zps8l5vsxql.jpg.html)
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Got a PC pipe on the way, its old and needs lots of repair but I think I can get this one looking nice as no one has tried to fix it before.
The cylinder head needs to come off to have the squish band cut deeper.
I got side tracked by my hotrod project and gave that a couple months work so nothing got done on the KX and I used all my money.
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White bends in plastic can be removed with a heat gun.... Careful.... 8-)
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White bends in plastic can be removed with a heat gun.... Careful.... 8-)
I tried that, I didn't do anything, they are too old, bend has been there for meany years, I have them a wet and dry sand and then a buff with a buffing wheel and they look ok now.
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Never ever use Canada post, everything on there web page is lies, been waiting 9 weeks for my parcel.
Other than that I have removed my cylinder head and a friend says he can hold it in the 4 jaw chuck to recut the squish band, and I will index the sparkplug wile its off, might make some undetectable difference in power.
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(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1845_zps7wzjzovf.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1845_zps7wzjzovf.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1846_zpst59iasom.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1846_zpst59iasom.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1847_zpsy0w4uzl4.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1847_zpsy0w4uzl4.jpg.html)
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Ordered a set of clutch plates and the friction plates came with a note saying they only had one steel in stock, so now I have a set of genuine steels on order from japan.
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Fished, bike has 3 hours on it now from tuning and only road use, its very powerful, when I open the throttle it just wheel spins and I have to lean fward to keep the front down.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1908_zpsnmpkvf4b.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1908_zpsnmpkvf4b.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1907_zpshtvekg2a.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1907_zpshtvekg2a.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1906_zpsmnfhqwph.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1906_zpsmnfhqwph.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1905_zpsm0bybuid.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1905_zpsm0bybuid.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1904_zps2lwolvlt.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1904_zps2lwolvlt.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1903_zpsswnp7syf.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1903_zpsswnp7syf.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1902_zpsxqmfvker.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1902_zpsxqmfvker.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1901_zpsrqb8phau.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1901_zpsrqb8phau.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1900_zpshzscr3vb.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1900_zpshzscr3vb.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1899_zpsvrw11p5l.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1899_zpsvrw11p5l.jpg.html)
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/IMG_1898_zps3cnhvgsi.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/IMG_1898_zps3cnhvgsi.jpg.html)
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looks good!
put a fresh rear tire on so it hooks up....then you'll really have to lean forward.
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That was quite the transformation. Looks great!
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The bike is looking good SOHC! Well done. Glad to hear of your power struggle. :lol:
P.S. Let me know how the radiators work out. I will be going the same route when I get to it. Did they fit ok, or did you have to massage them a bit? Are they GPI?
Ed
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Radiators are very good, engine stays cool even after a hard run, no boiling etc, no leeks yet to.
That rear tire was mint when I got the bike, now its destroyed, I will get something more suited to the road next but it will destroy that to I bet.
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I will get something more suited to the road next but it will destroy that to I bet.
you making it street legal?....or just out do'in some good ole fashioned fun illegal street hawkin? :evil:
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I will get something more suited to the road next but it will destroy that to I bet.
you making it street legal?....or just out do'in some good ole fashioned fun illegal street hawkin? :evil:
LOL just illegal street use, i never plan to use it off road ever :)
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LOL just illegal street use, i never plan to use it off road ever :)
[/quote]
Why? :?
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LOL just illegal street use, i never plan to use it off road ever :)
don't want to get it dirty eh? :lol:
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Yes I dont want to make it dirty.
The CDI has failed for some reson, I replaced a bad source Coil and now the CDI packed up
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Yes I dont want to make it dirty.
The CDI has failed for some reson, I replaced a bad source Coil and now the CDI packed up
You realize it is a DIRT bike it's okay for it to get dirty! :? :lol:
Kawasaki makes street bikes too
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CDI is good I just had the source coil wired round the wrong way, its sparking now.
I don't think Kawasaki have ever made a road bike I like the look of.
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Glad u got it fixed!! If it's going to only be on the street don't waste money on any kind of knobbies
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If you want to ride road but also still want something that can perform well offroad I highly recommend the Mitas E-09 tire. I have it on the back of my Suzuki DR650 and I have taken that bike to hell and back and I wont ride another tire for on and offroad use. I was worried about it on the road and in wet conditions and was very surprised at how well it grips on the road. They make them in 19".
But if you are not interested in dirt at all then I go with what Reklessj suggested. :-)
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Yes using knobbys on the street is a wast of money and they don't corner to well, I have worn all the center knobs down and a few of the side ones have been ripped off.
What ever tire I have on the back is going to get a hard time but I will get some kind of on / off road tire.
My old workmate would use a tire for one ride then change it and put it under the house and he has a stack of them, I might ask if I can have a few to use up.
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Sad day today, I have officially sold the bike, I am too sick to ride it and I need the money for a trip for my wife
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That's a shame I enjoyed watching you build up the old bike. All the best to you and your wife.
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Sad day today, I have officially sold the bike, I am too sick to ride it and I need the money for a trip for my wife
bummer man!...
well, you'll just have to get another "fixer-upper" once you get better, and do it all over again. :mrgreen:
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I hope you get to feeling better SOHC. I really enjoyed your build thread and hope you get to start a new one soon. Please keep us updated on how you're doing.
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I will do an old KX 420 or something next, something air cooled, I miss my old 1975 KX125.
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Sorry to hear that man. Hope you get better soon and that there will be a bigger, better, badder build down the line.
Ed
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I will do an old KX 420 or something next
there ya go!...I'd love to find an '81 420 myself, to do over...or an '80, but I like the '81 more.
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I have CFS witch makes off road riding very hard, I don't ride for more than 40 mins on my road bikes, I have improved over the last 3 months witch is good,
But yes next project is a KX 420 or early 500, I would have to import one as they were rarely sold here new, they were too powerful or expensive or something.
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This is off a 1993 but it was cheep so I grabbed it, but I think it will fit.
(http://i354.photobucket.com/albums/r401/castinbronze1rudolphtrc/415225739_zpsj38mtyws.jpg) (http://s354.photobucket.com/user/castinbronze1rudolphtrc/media/415225739_zpsj38mtyws.jpg.html)
Hello mate, do you know where I may be able to find one of those 93 Seat Covers? Would really suit my 1993 KX 250 restoration. Thank you!!!!
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Loved the 90 model rebuild. You are highly skilled and worked so well with what you had. It was interesting to see you work with the parts and problems you had to build a really great bike complete with all its imperfections. I bet that bike was a weapon!