87 KX 250 Power valve setup....

[dinkyguitar]

Hi All,

I was taking my power valve assembly apart and noticed some things.

When the rod is pulled all the way out 1 valve I could see fully opens while the other a 1/2 way open.

So I looked on my manual and there's "supposed" to be alignment dot marks on both power valve gears, which there are none.

One has a tooth that is lower, which I assume is an alignment mark. The other gear literally has nothing??

After thinking about it, I noticed there was a scribed line on the valve rack on both sides. So with the rack fully out, I aligned the lowered gear tooth with the scribed line and on the other valve, I just put it so when the rod is pulled out both valves are fully open.

When the rod is fully closed both valves are closed and the flat side of the valves are facing forward.

Is all this correct?

1 last question.

I was able to find the o rings that sit on the bottom of the valve guides....but not the o rings that sit in the groove of the valve guides. All the parts catalogues I saw don't list any o ring ther.....just the entire valve.

Where can I get these o rings?

dinky,

[Foxx4Beaver]

sounds like you got it figured out correctly...good job!
as for your 2nd question...never heard of or seen O-rings on the "bottom" of the guides on any 250 I ever owned, only the ones in the grooves....can you post some pics of exactly what you're referring too?

then again, I never owned an 87, so anything's possible. 

[dinkyguitar]

They are sandwiched between the jug and crankcase gasket:

http://www.partzilla.com/parts/search/Kawasaki/Motorcycle/1987/KX250-E1+KX250/CYLINDER+HEAD-CYLINDER-REED+VALVE/parts.html

They go under the valve guides...

Anyone know where I can get replacements?

Mine "look" pretty go, but I'd rather get replacements instead of reusing them.

dinky,

[Foxx4Beaver]

if you're referring to the #92055-022 O-rings...those are the ones that go into the grooves of the guides....my 2000 250 is the exact same way and uses the exact same O-rings/part numbers.

I'm thinking a previous owner may have been trying to shim the valves in some way by using extra O-rings...out of the 8 different KX250s I've owned, never heard/seen anything "under the guides".

[dinkyguitar]

Yep....those are the ones....but it makes sense now.

The ones on the bottom that I'm talking about were orange, and the ones in the valves are black. I tried to see if the orange ones fit in the valves but they seemed a little big....but then again I was concentrating on getting the power valves to work properly.

There was also some kind is silicon on them when I removed them. I'm wondering if they were leaking?

I'm curious how poorly the engine ran considering these issues.

Hey, thanks for helping me figure this out!


dinky,

[Foxx4Beaver]

Hey, thanks for helping me figure this out!
dinky,

no problem...but I'm kinda in the same boat as you...like I said, I've never owned an 87, so I'm wondering if I'll learn something new too...hopefully someone that has/had an 87 can shed a lil light on it....but the fact that you said the O-rings that were under the guides were orange, and for the fact no Kawie site lists these extra O-rings for the 87, AND for the fact that you said there was "silly-cone" in there, tells me that someone else was in there before you doing some odd things

[dinkyguitar]

Well, it was definitely taken apart since the cylinder was honed...

I don't think the case was ever split though.

I'm going through every but and bolt anyway since the bike sat for 8 years....

And basically replacing everything  .

dinky,

[Foxx4Beaver]

And basically replacing everything  .
dinky,

though expensive...that's the only way to go if you plan on keeping it for a while

[bens87braap]

http://www.oemmotorparts.eu/oem5.asp?M=Kawasaki&T=KX%20250%20%20KX250&Y=(E1)%20%20E1%20%201987&L=KA2_KX%20250%20E%20%20%20KX250%20%20%20E1&O=CYLINDER%20HEAD_CYLINDER_REED%20VALVE&F=KA2_KX%20250%20E%20%20%20KX250%20%20%20E1%20%20_CYLINDER%20HEAD_CYLINDER_REED%20VALVE&L2=KA2_KX%20250%20E%20%20%20KX250%20%20%20E1%20%20_CYLINDER%20HEAD_CYLINDER_REED%20VALVE

These guys have em in stock  Keep us posted allways love a 87 rebuild

I havnt bought items from them i just use the page as a listing of parts

[bens87braap]

87 power valves dont have a punch mark to line up but if u look closely u might see 1 gear that has a tiny cut out at the top of the gear its hard to see mine are like that well whats left of em lol

You could allways send me the left one and Ill make sure it works fine hehe

[AB517]

sweet.  I am rebuilding a 87 kx 250 also. 

My brother in law raced it in 87 - 89. Then it was a second bike for awhile.  Sat since 99 or so. started it and ran it in the summer of 13.  I am basicly taking it apart and cleaning the parts and trying to put what I can back on. 

Cylinder looks ok, all bearings good so far.  Wire wheel and elbow grease and she is getting shinny again.

Two questions.

Is the orig rear mud flap yellow?

where can I get "cheap" plastic? right radiator shroud broken.  junk yards maybe?

[bens87braap]

Original 87 was all green plastics including rear mud guard as far as I no.  U can see in my pic I broke the right side rad shroud but i have the original ones and an after market set of UFO I got for 100 bucks

Heres a set for $85 new  http://www.ebay.com/itm/UFO-KAWASAKI-KX-250-500-1987-RADIATOR-SCOOPS-2703-/280404146328?pt=UK_Motorcycle_Parts&hash=item414963b898

UFO make all the plastics just keep searching sometimes they are their sometimes not .

Original rad shrouds decal
http://www.ebay.com.au/itm/Kawasaki-KX-250-KX250-1987-Pre-Cut-Rad-Decals-Graphics-Stickers-/390841013966?pt=UK_Motorcycle_Parts&hash=item5afff096ce&_uhb=1

[queen of spodes]

Mud splash was black on all OEM kx's.  Green is/was aftermarket.

[bens87braap]

I never seen Brand new KX with black all my pics are green



My Dad bought me a brand new 125   kx  1987 it was all green bought the bike in 88

[AB517]

I have one word for you people ...

You Guy are AWESOMEEEEE     

thanks. 

Limited budget = time  But 90% of the bike will be original, a little worn, but original.