My 88/91 KX250 project

[1989kawasaki]

you have to take the return spring out of the hole holding it on, then twist it so it clears the clutch basket, remove the return spring, turn the shaft counter clockwise , it should pull right out. then obviously remove the circlip holding the ratchet spring on then remove the spring. also check the condition of the ratchet teeth. will those instructions work for ya?

[Caddy 16v]

yes thanks that should work, will check it tomorrow!

[Caddy 16v]

YIEHHHAAAA my monster came alive muhahahahaaa, loud as hell without a muffler but I just couldn't resist trying to start it!!

I switched the whole kickstart assembly with another one and it now works flawlessly, the teeth on the one in there were quite worn!

Now onto the rest of the bike, just need some more parts and it will be done.

[1989kawasaki]

good im glad its fixed now, if it ever slips then it will be that spring.

which parts do you need?

[Caddy 16v]

To be able to ride it, I'll need a chain, muffler, the nut at the side of the swingarm bolt, rear brake pads and the bolt that holds the rear brake pedal.

Then to finish the bike it needs a rear fender, killswitch, front number plate, fork protectors and it needs the forks and shock rebuilt to let it loose on the motocross track.

Tomorrow I'll probably put evenything on that I can... it won't be pretty but that'll come later, all I want is something to ride right now.

[Caddy 16v]

So this is as far as I can go right now, to say that it is UGLY is an understatement to get the engine running was the biggest priority! I'll get the rest of the parts and graphics kit as I go along and have money available.






Here is a pic of the worn ratchet:

[1989kawasaki]

youre right! UGLY is an understatement. you need a new: seat , side covers , rad shrouds.

[Caddy 16v]

But before that it'll get a silencer, chain, rebuilt rear master cylinder and some other nuts and bolts. Might just get a graphics kit later on instead of new plastics, that'll cover it up, the full plastics kit is not exactly cheap compared to the newer bikes.

I could call it a rat, looks abused but other than that fully functional, just imagine the looks on ppls faces when they get overtaken by it.

[Marco810]

haven't ever tried to touch up old plastics but i see theirs alot of methods/product floating around that seem to work. might be worth looking into

[Caddy 16v]

So I got a little update, got the silencer off a '92 and it fits, ordered a chain a while ago and the rear fender is also on they way plus some rear brake pads.

But there is one thing that concers me, I took the pipe off to put that copper gasket in and I could see a drip of anti freeze / coolant where the cylinder meets the pipe!

I searched around and the reasons I came up with are head gasket or the crank seals, or is it normal after a rebuilt? It barely has 10min of run time! I don't think it smokes like crazy, the only thing it did was leaking some oil goo onto the pipe which I thought was normal from not having that gasket in the pipe.

Any help/ suggestions? I don't want the engine to blow after I spent all that money on it


Thanks, Bjoern

[Caddy 16v]

...I ran it a bit more today and got the chain, so I was able to take it for a little ride, after that I took the pipe off again and there was no more coolant to be found inside, so I guess I got lucky. But it's running way too rich and doesn't really want to get on the pipe, so I'll have to play around with the jetting.

[Caddy 16v]

This is how it sits now, just waiting on the rear fender:



And my dilemma with the missing throttle stop screw, hope that one won't take too long to show up, I bet when I get it, it will be raining for days on end

[Caddy 16v]

Alright, finished it up tonight, I think I won't bother with a graphics kit at this point, maybe further down the road, now it's riding time!

[Motorrad]

Nice..

I think you need more stuff for your bench... I can see it in a few spots...

[Caddy 16v]

Hehe thanks, it's the shop of my "Grandpa in law" he had a logging company so I can't really start cleaning up in there, there is actually another work bench where the bike is pointing to.