2004 KX 250 Rebuild

[DP3601]

I finally found a 2004 KX 250 that I can spend some time to clean up.  It is a little rough but for the price I couldnt pass it up.  The engine was completely rebuild by a dealer, he provided the bill and I called the dealer to verify it.  Engine wise I should be good to go.

[sandblaster]

Cause they want to go riding really bad, didn't plan ahead, waited till the last second, didn't want to buy new parts because their second cousin thrice removed had the same bike in parts... ect ect.. 

[DP3601]

Cause they want to go riding really bad, didn't plan ahead, waited till the last second, didn't want to buy new parts because their second cousin thrice removed had the same bike in parts... ect ect.. 

I have to say at least they used all of the correct threads and everything is in tact that way.  I will have to be a happy guy with that!

[DP3601]

This is the first question I have if anyone has some insight.  This doesnt look broken off where the brake slides on but it does look worn down.  Shouldnt it be alot taller of a edge to keep the brake in place?

Also wasnt 2004 the one of the years that Kawasaki and Suzuki had their partnership and shared parts?

[umberto]

Man I love my 04, they're great bikes.  I think the 03s handle a little better, but the 04s run better.

I have seen some pretty crazy things people do to dirt bikes on the few flips I have done.  My son and I call it getting Craiged, both to honor a guy we knew that was rough on his bikes and Craigslist in general.  It's always fun to spot where someone got Craiged on their bike, and make them find it too.  Sounds like the mystery parts are the only Craiging you got on this bike.  It looks really nice.

[Foxx4Beaver]

Nice score DP.

When I got my '00 that was in pieces a few years ago...that belonged to a 14yo kid, I had the same mess of parts that didn't go with the bike. The biggest was the expansion chamber....it had an FMF pipe from a '94 KX250...I realized it once it got to that point in the assembly, when none of the mounts where lining up. Then it donned on me, why both spring eyelets on the cylinder where worn right through from the springs....cause that's all that was holdin the dam pipe on. sigh 

[DP3601]

I think Ill add Craiged to my vocabulary Umberto!    and Ill bet that thing had some good vibration to it Foxx!   I know I am gonna find something on this bike that bites me but so far just the swing arm in the only thing I am concerned about! 

[Foxx4Beaver]

and Ill bet that thing had some good vibration to it Foxx!   

honestly I don't know...I got it in boxes...but after dropping $3500 into it...it literally sounds like it came off the showroom floor...absolutely zero rattles. It's amazing.

[DP3601]

Well here is a big surprise.  Called the dealer that I talked to initially when I bought the bike and questioned why they didn't mention this.  They reassured me that it was repaired well and the engine had no leaks.  I have yet to do a leak down test on it to make sure.  

Anyone have any experience with something like this or would I be better to find a new case half and replace it?  Checked on a new one from Kawasaki and they come as a set for nice price of $532

[sandblaster]

I have repaired many, many cases with no issues.
You do need to machine the mating surfaces and or lap them to make sure they seal well.

[DP3601]

I have repaired many, many cases with no issues.
You do need to machine the mating surfaces and or lap them to make sure they seal well.

Thanks Sandblaster you let my anxiety go down a bit! I will do a leak down test and if it checks out then it should be good to go for now on the engine.

[DP3601]

I finally got a chance to spend some time on this thing the past week.  The good news is I did a leak down test and the engine is tight!  Big relief and a job well done from the guy that fixed the cases on this thing in the past!  I would buy him a few cold beverages if I knew who he was.


I worked on the linkage and got it looking alot better then stock.  I have a little touching up to do but definitely better.

[zz3gmc]

I just picked up a 04 KX250 basket case. May have it up next year as a 300.

[DP3601]

I just picked up a 04 KX250 basket case. May have it up next year as a 300.

Are you posting pics on here zz3gmc as you do it?  I would like to see how your coming along with it over time!

[umberto]

I just picked up a 04 KX250 basket case. May have it up next year as a 300.

Who makes a 300 kit for it?  Just asking for a, uh, friend, yeah, friend.