Craigslist Find Project

[umberto]

I was taking a break at work yesterday, and I stumbled upon this 2003 KX250 that was labeled "Project Bike" on Craigslist.  It appeared to be in pretty decent shape, but the engine was blown (notice the tow strap in the picture):



I went to meet the guy at his shop and realized the bike was pretty nice.  He had taken the motor out and pulled the cylinder off already.  The stock piston had cracked off at the skirt, but the bottom end was in excellent condition (no play).  The cylinder showed minimal wear, and the exhaust valves moved freely.  It has a Pro Circuit pipe and silencer, ASV levers, and Acerbis hand guards and bark busters.  I have a ton of spare parts for a 2003, so I will be able to rehab it without a lot of new stuff.  I talked him down to $700 and took her home.

The first step was a bath:



I'll be splitting the cases, cleaning out the debris, and checking the seals and bearings on the bottom end next.  Hopefully it will be a fun little project that I can flip down the road.

[DP3601]

Im still looking to find a 03 or 04 KX 250 to build up like I did my 125.  Keep us up to date with pics on your project!

[sandblaster]

+1 

[umberto]

I got pretty lucky with this one.  It had been on Craigslist for three weeks, and a bunch of guys had gone to look at it.  They got scared off because it was in pieces.  I thought it just saved me a step.   

[umberto]

I decided to divide my project into two parts.  Part one was swapping upgraded parts on to the bike, and part two will be engine rebuild and mechanical.  Today I was able to swap on a set of forks that I had that had been re-valved by ESP suspension.  I bought them on eBay for my KDX Hybrid, but I ended up going a difference direction.  I had all the shrouds, front fender, and fork guards from my KDX that were collecting dust.  I swapped over my wheels from the KDX as well, as I was planning on replacing them with some Tusk Impacts anyway.  I added new front brakes pads that I had from another build, left over Renthal bars from my son's 125, and the front end was done.  

In the rear, I swapped over the old shock from Goliath because it was recently rebuilt and identical to the one on this bike.  I added a new Acerbis chain slider and bottom block that I had from another project.  I added a new rear sprocket and the rear wheel from the KDX.  The seat is the cover and foam from my son's 125 that he swapped out for a softer foam.



I redid the rear plastic by sanding with 600 grit paper and water.  I brought back the shine with PC Racing plastic renew.  I was really pleased with how they turned out.



It was a fun day in the garage.  It was like I was playing scavenger hunt all day trying to find stuff I could use.  So far the only things I don't have are the wheel that goes inside the throttle housing, and a rear brake lever (if I can't fix it).  The only expenses I have incurred so far are $10 for new grips.

Tomorrow I will be cleaning up the engine, splitting the cases (there is a large chunk of piston under the rod), and rebuilding it.  I will be using a Wossner piston and rings, Wiseco rod bearing, and Cometic gaskets.  I have a new chain and front sprockets, and new pipe o-rings and springs.  I snap some more pics tomorrow, and if all goes well maybe a video.

[umberto]

The reason I swapped out the wheels is because the other ones had been painted with what appeared to be an undercoating paint.   

[umberto]

I got the motor apart today, and was sailing along when I caught this out of the corner of my eye.  It's a small crack on the clutch side case.  It goes through to the other side.  Should I replace this case just to be safe, or is this not serious enough to warrant a replacement?  Everything else is in excellent condition.

[umberto]

Could I have the crack welded on the back side, or use an epoxy to hold it together?

[sandblaster]

I hate epoxy on cases.... But that's probably because I run into it so often.
I would V out the crack, tig weld it, then resurface the mating surface.
No worries after that..

[umberto]

Thank you for the reply Sandblaster!  I'll get it welded up and move forward.

[DP3601]

That plastic turned out looking great!  Ill have to try that on some of my old plastic for my 125.  I have always been a fan of the gold rims. Much better than the black.  Looking great and not spending much! 

[umberto]

Thank you DP3601. I was really surprised how well it turned out, and it didn't take that long either. I'm going to have to do the front number plate though, because the side panels make it look dull. 

[umberto]

I forgot to add this shot when I was posting Sunday.  I don't think this one is salvageable.  

[umberto]

So I got the cases welded up at my local welding shop.  I think it turned out really nice, especially after I filed it down.  I put the cases together and there was no light coming through, so I was pretty satisfied.  



I finally had to spend a little money on the bike, but I think it will all increase the value.  I added upper and lower chain rollers, chain and sprockets, all new factory Kawasaki shifter and kickstart seals, sprocket seal from Cometic, Tusk magnetic oil drain bolt, Tusk clutch perch, Tusk vent hose, Tusk kill switch, and FMF pipe springs and o-rings.

The motor was treated to a new right side bearing (the one in the motor came off with the crank and I just didn't want to chance it), Wossner Piston, and Cometic gaskets.  



I worked for about 10 hours today, but wasn't able to get to starting the bike.  The crank threads on the ignition side are a little boogered, so I am going to order a left hand thread die to clean them up.  I got a ton done even without starting the bike.  All I have left is to put the ignition on, connect it, add the radiators, and put on the pipe and silencer.  Then's it's out for a break in, and back on Craigslist.  The best part is this counts as selling a bike, which I assured the very patient Mrs. Umberto I would do.  

[umberto]

I also found these for the swingarm.  Kawasaki stopped making the swingarm graphics, and the bike only had them on one side.  I don't have any extra swingarm graphics, but I think these will work nicely.