2004 KX 250 Rebuild

[DP3601]

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.   

Someones ears just perked up.....Ha

[DP3601]

The left side radiator is twisted on this thing.  Does anyone know of anyone good that can rebuild these or is it better to replace them.   If so who would you guys recommend to get a new one from.   

Thanks guys

[sandblaster]

http://www.oem-cycle.com/forum/viewtopic.php?f=40&t=136&hilit=radiator

[zz3gmc]

Powerseal USA did the 295 kit. The bike is supposed to be a backup to my wifes 04 KX300 or 295 but after she rode my recently refurbed 04 KX250/500 she may want one for herself! As far as pics of the rebuild Ill try to remember but I usually dont take too many pics during any builds.

[DP3601]

http://www.oem-cycle.com/forum/viewtopic.php?f=40&t=136&hilit=radiator

Thanks I think I can do that!

[DP3601]

I am finally getting back to working on this thing.  Took a dirt sample and have been down and out with the bum shoulder, but I was at a race last weekend and talked to a guy that had done the conversion on his 04 KX250 to the 2017 plastic.    He inspired me to get the 2017 plastics to fit.    Great guy and gave me lots of information. 


I have found most of the parts but still am in need of a 2016/17 kx450f fuel tank and air box assembly.   Does anyone have one of these just laying around they would want to part with? 

[DP3601]

I was getting ready to post updated pics of the 250 but photo bucket isnt letting me do that anymore.  Is there a different way to do this?

[umberto]

I'm working on some things.  Photobucket just decided overnight to disable their third party hosting for everyone that uses the site.  You can still view the pictures by right clicking on the picture and opening in a new window or page.  There are a couple of other sites that host pictures, we just need to put instructions out there on how to do them.  I'm going on vacation this week, so it will be mid August before I can get anything together.

[DP3601]

Back to working on this thing, I had a little shoulder issue from a riding incident that slowed me down.  Finally glad to have use of the wing again

[DP3601]

I worked on the linkage some more and got a lot better finish to it, alot of hand work but man it turned out good!

[DP3601]

Also had a buddy get the engine looking better than it has in years!

[DP3601]

I am trying to find the air boot that comes off the carb to the air box on this 2004 KX250.  Kawasaki has no more in stock new.  I have found a couple on ebay etc but was wondering how much did they change them between 04 and 05?  The part numbers are different but look similar.  Any ideas or anyone have any information on this? 

[sandblaster]

I believe 05-08 use a different style then the 04 and earlier.
Would they still bolt up?
I'd look at the gasket interchange info but my bet is that they are significantly different...
Someone on here knows for sure...