My 88/91 KX250 project

[Caddy 16v]

hi,

I got a free 88 and 91 KX250 given to me a while back, I'm in the process of rebuilding the 91 one first. So far I got the cylinder bored and got some parts ordered. I will be updating the pictures as I go. Next up is the frame and putting the engine back together. I'll let the KX500 swingarm on the 91 to see how it handles. So far it has been a great learning experience

[Caddy 16v]

So I made some progress, assembled the engine, put some newer handlebars on it plus grips and levers, next up is painting the frame and fabricating the top engine mount plus the cooling system.

[Caddy 16v]

Got the frame painted, the engine assembled and put in for now, next is the cooling system when the parts arrive

[Caddy 16v]

Made some progress:

Bolt kit:






Still waiting one some parts to finish it so I can test the engine, also the plastics are really dull and worn by the sun, any tips on how to improve the looks? Will a heaadlight restore kit work?

[1989kawasaki]

i bought the same bolt kit from motorsport fasteners for my 89 kx250

[Caddy 16v]

Yep its a good kit only the sub frame bolts are missing I think.

[Caddy 16v]

And some more progress:





Also cleaned the plastics with some magic eraser, they look much better now even though they are old. I'll need to use the heat gun on them some more:


My doggy is helping:

[1989kawasaki]

you shoulda gotten the cylinder media blasted or whatever they do to it when they replate the cylinder. it makes it look brand new

[Caddy 16v]

I might soda blast it once I know its all running right, right now I just want to all make it work, after that it will be about looks

[1989kawasaki]

I might soda blast it once I know its all running right, right now I just want to all make it work, after that it will be about looks

i think you ought to . its all about looks for me

[Caddy 16v]

So, I had it all ready to go today for the first start up, wasn't fully assembled but enough to let it run and as I tried to start it my freaking kickstarter slips the whole time, sometimes it would engage a little bit, but it was no where enough to get the bike started so now its all in pieces again and I'm trying to figure out what the problem with that ratchet is. How annoying, could have just been the cold weather but I never had problems like that with other bikes in winter... and what a waste of oil and coolant, I'll just get some ATF type F tomorrow... just had to vent a little bit

[1989kawasaki]

change the ratchet spring

[Caddy 16v]

is the ratchet spring the big one at the end, or? I still have two others laying around so hope that will work.

[1989kawasaki]

the big spring is the return spring. pull out the kick shaft and at the back of it there is a circlip and a small spring  in there. go look then tell me if you found it.

[Caddy 16v]

Ok I found it on the parts diagramm, so can I just pull out the kick shaft or what? there is nothing holding it in place?