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Author Topic: 90 KX250 rebuild  (Read 57011 times)

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Offline sandblaster

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Re: 90 KX250 rebuild
« Reply #60 on: October 07, 2015, 01:02:00 PM »
Quote from: SOHC on October 07, 2015, 11:11:08 AM
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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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline SOHC

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Re: 90 KX250 rebuild
« Reply #61 on: October 07, 2015, 08:01:14 PM »
Quote from: sandblaster on October 07, 2015, 01:02:00 PM
Quote from: SOHC on October 07, 2015, 11:11:08 AM
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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Offline SOHC

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Re: 90 KX250 rebuild
« Reply #62 on: October 08, 2015, 12:38:20 PM »
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.     



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.   

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Offline SOHC

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Re: 90 KX250 rebuild
« Reply #63 on: October 14, 2015, 09:00:06 PM »
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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Motorrad

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Re: 90 KX250 rebuild
« Reply #64 on: October 15, 2015, 01:54:59 AM »
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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Offline SOHC

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Re: 90 KX250 rebuild
« Reply #65 on: October 15, 2015, 04:31:21 PM »




All together, I used locktite and I hammered the ends of the bolts so they will never come out. 
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Offline SOHC

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Re: 90 KX250 rebuild
« Reply #66 on: October 15, 2015, 04:33:43 PM »


Cut them out this morning, total cost to make 0$  

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Offline SOHC

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Re: 90 KX250 rebuild
« Reply #67 on: October 15, 2015, 04:35:48 PM »




Made this from the old clutch plates, I like to use this over my rattle gun. 
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Offline SOHC

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Re: 90 KX250 rebuild
« Reply #68 on: October 15, 2015, 04:47:59 PM »
This is off a 1993 but it was cheep so I grabbed it, but I think it will fit.

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Offline sandblaster

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Re: 90 KX250 rebuild
« Reply #69 on: October 15, 2015, 05:51:01 PM »
Very nice work on that basket.
Can't wait to see the finished product.
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline ecdeyzel

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Re: 90 KX250 rebuild
« Reply #70 on: October 15, 2015, 06:40:31 PM »
Nice work SOHC!
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2007 Suzuki DR650SE
1999 Kawasaki KX250 (Rebuild in Progress)

Offline ecdeyzel

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Re: 90 KX250 rebuild
« Reply #71 on: October 18, 2015, 06:41:14 PM »
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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2007 Suzuki DR650SE
1999 Kawasaki KX250 (Rebuild in Progress)

Offline SOHC

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Re: 90 KX250 rebuild
« Reply #72 on: October 19, 2015, 08:14:54 AM »
Quote from: ecdeyzel on October 18, 2015, 06:41:14 PM
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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Offline ecdeyzel

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Re: 90 KX250 rebuild
« Reply #73 on: October 19, 2015, 07:13:00 PM »
Quote from: SOHC on October 19, 2015, 08:14:54 AM

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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2007 Suzuki DR650SE
1999 Kawasaki KX250 (Rebuild in Progress)

Offline SOHC

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Re: 90 KX250 rebuild
« Reply #74 on: October 20, 2015, 07:40:52 PM »




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