My first 2 stroke build!!

Junebug833
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Junebug833
Edited Date/Time 11/19/2015 8:50am
Hey guys im excited to start my first build of a 2003 KX250. Im picking it up on Sunday! I do have a few questions though...is 03's pretty compatible with the 05-07's? The bike is nearly completely torn down. Its pretty much a frame with the motor and suspension on. The rest of the bike is in boxes. Im excited to start but i'm even more excited to get it to the finished product! Any help or input is appreciated!!





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reded
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reded 2/27/2015 6:06pm
2/27/2015 6:06pm
If you want it to be legit, take your time and don't plan on finishing it for 2-3 months. I've got a 2000 CR that I've been working on since Jan 1. It started out as the biggest POS I've ever touched but after many hours of rebuilding, reshaping, sanding, polishing and deciding where to best spent money it's starting to make me proud of the end result. I wish I'd taken more pics as the ones I have don't do it justice in the beginning or end. Parts that have been fixed or replaced include,
Exhaust
Entire brake systems including rear pedal
ALL bearings
Tires
Rear wheel
Front wheel
Suspension-both ends
Throttle housing
All Cables
Kick starter
Shifter
Clutch perch and lever
Grips
Carb
Plastics
Repaired airbox
Chain guide
Chain rollers and slider
Seat cover
Chain and sprockets
Tires.
Radiators
Various hardware

Somehow, after purchasing the bike and parts I'm "only" into it for a little over $1700. No way I can buy a bike with this many new parts for $1700 and I've had fun restoring an old dog back into a new pup.

The last pic is a couple days ago and I've yet to get the new tires mounted along with all of the new front end plastic. I'll be sure to post pics of the end result.













BD233
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BD233 2/27/2015 6:41pm
2/27/2015 6:41pm
I'm currently doing my 2003 KX250 as well. Parts are so cheap for these bikes...Fleabay is your friend. Good luck with the build. Looks like a solid starting point.
Junebug833
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Junebug833 2/27/2015 7:43pm
2/27/2015 7:43pm
Thanks guys and I've been following your build BD233 it looks good so far and reded thanks for the input definitely going to take my time and so it right! The cr looks sick!
BoGT12
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BoGT12 2/27/2015 9:03pm
2/27/2015 9:03pm
I thought 03 was a one off year?

The Shop

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Junebug833
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Junebug833 3/8/2015 11:07am
3/8/2015 11:07am
Hey guys just a little update on how it's going. When I got the bike home I went through all 3 boxes of stuff the cake with it and I've come to the conclusion that this bike hasn't been torn down and greased since it was pulled off of the showroom in 2003. The rear linkage arm bearings that are in the Swingarm where completely packed with dirt I had to take a hammer and a screwdriver to knock the metal sleeve out. So far this is list of things I have bought for it:

1 Tusk 8mm bolt kit
1 Tusk 6mm bolt kit
1 Tusk assorted bolt kit (all three were from RMATVMC)
1 Bolt KX/KXF Pro Pack (excellent customer service)
1 No Toil air filter
2 MSR Levers
1 Motion Pro Titan throttle tube
1 Clutch Cable
1 OEM flywheel but
3 OEM stator screws
2 OEM radiator louvers
Tag grips
Renthal 7/8ths bars
Primary Drive Chain and sprockets
Replacement chain guide blocks
Throttle cable
Main jet
Moto Hose hose replacement kit
Acerbis black plastic kit
Cycra flo green stadium plate
Cycra flo green front fender
Galfer SS brake lines
Bridgestone M404/M403 tires
FMF Fatty
FMF Shorty
And a few other assorted items...
As for now I made it into a roller so I can bring it to my friends garage to put it all together!!!



Junebug833
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Junebug833 3/10/2015 5:34pm
3/10/2015 5:34pm
I got the bike down to my friends house and we took the head and cylinder off to find this...the nikasil is completely worn through to the aluminum so now I have to send the cylinder out to PowerSeal USA to get NikaSealed.


Hondas4Life3
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Hondas4Life3 3/11/2015 7:42pm
3/11/2015 7:42pm Edited Date/Time 3/11/2015 7:46pm
That piston looks brand new. I have never used Powerseal but Millennium has a deal right now where you can get %25 off in stock wiseco top ends if you send in the cylinder for nikasil replate.. Make save you a few $.
Junebug833
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Junebug833 3/12/2015 9:48am
3/12/2015 9:48am
Thank you for the info! They didn't tell me that on the phone when I spoke with them yesterday. I'll have to look in to that. The piston is a brand new B piston from Vertex.
Hondas4Life3
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Hondas4Life3 3/12/2015 9:52am
3/12/2015 9:52am
Junebug833 wrote:
Thank you for the info! They didn't tell me that on the phone when I spoke with them yesterday. I'll have to look in to that...
Thank you for the info! They didn't tell me that on the phone when I spoke with them yesterday. I'll have to look in to that. The piston is a brand new B piston from Vertex.
That's a shame. You cannot reuse it after you replate the cylinder. Have them match it to a new wiseco
Junebug833
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Junebug833 3/12/2015 9:55am
3/12/2015 9:55am Edited Date/Time 3/12/2015 9:56am
When I spoke to PowerSeal they said they could replace the cylinder to fit the new piston??
Hondas4Life3
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Hondas4Life3 3/12/2015 9:58am
3/12/2015 9:58am Edited Date/Time 3/12/2015 9:59am
Junebug833 wrote:
When I spoke to PowerSeal they said they could replace the cylinder to fit the new piston??
A NEW piston. Not the new one in the engine already. You ran that piston in a cylinder that needed replated therefor it's probably no good. If you are going to replate I would replace the piston, rings,And circlips. I wouldn't want to put a used piston in a freshly played cylinder.
Junebug833
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Junebug833 3/12/2015 10:00am
3/12/2015 10:00am
Thats what I meant to say...the piston in the picture is brand new it has 0 hours on it. PowerSeal said they can plate the cylinder to fit the piston in the picture since it is brand new.
Junebug833
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Junebug833 3/12/2015 10:04am
3/12/2015 10:04am
The guy I bought the bike off of put the piston in the bike like a month ago when he put the motor back together.
Hondas4Life3
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Hondas4Life3 3/12/2015 10:14am
3/12/2015 10:14am
Junebug833 wrote:
The guy I bought the bike off of put the piston in the bike like a month ago when he put the motor back together.
Oh okay. Yeah they will match it to a new one.
Junebug833
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Junebug833 3/12/2015 10:21am
3/12/2015 10:21am
Yeah he was going to run it till it blew I guess... Haha I'm not willing to take that risk
Junebug833
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Junebug833 3/16/2015 3:20pm
3/16/2015 3:20pm Edited Date/Time 3/16/2015 3:21pm
Today I got my email proof of my graphics for it!! Pretty excited how they turned out! It is an exact replica kit of my 13 KX450f so pretty pumped to have matching kx's. The proof doesn't show all of the hologram and chrome accents that are actually there.



Spagina767
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Spagina767 3/17/2015 7:51am
3/17/2015 7:51am
Seems like this is going to be an awesome build.
Junebug833
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Junebug833 3/17/2015 8:08am
3/17/2015 8:08am
Spagina767 wrote:
Seems like this is going to be an awesome build.
Thank you I really appreciate that. its coming together nicely.

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Junebug833
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Junebug833 3/17/2015 3:50pm
3/17/2015 3:50pm
Got the new chain tensioners in after re-drilling the holes out and put the back wheel on with the gold chain and sprockets and bled the brakes today. It's coming together slowly but surely. Next I have to put on the front fender to align the front end and tighten down the head set.



Junebug833
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Junebug833 3/17/2015 6:19pm
3/17/2015 6:19pm
Got my front number plate graphic on...just a little sneak peek of what's to come



jmc2
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jmc2 3/18/2015 9:14am
3/18/2015 9:14am Edited Date/Time 3/18/2015 9:15am
reded wrote:
If you want it to be legit, take your time and don't plan on finishing it for 2-3 months. I've got a 2000 CR that I've...
If you want it to be legit, take your time and don't plan on finishing it for 2-3 months. I've got a 2000 CR that I've been working on since Jan 1. It started out as the biggest POS I've ever touched but after many hours of rebuilding, reshaping, sanding, polishing and deciding where to best spent money it's starting to make me proud of the end result. I wish I'd taken more pics as the ones I have don't do it justice in the beginning or end. Parts that have been fixed or replaced include,
Exhaust
Entire brake systems including rear pedal
ALL bearings
Tires
Rear wheel
Front wheel
Suspension-both ends
Throttle housing
All Cables
Kick starter
Shifter
Clutch perch and lever
Grips
Carb
Plastics
Repaired airbox
Chain guide
Chain rollers and slider
Seat cover
Chain and sprockets
Tires.
Radiators
Various hardware

Somehow, after purchasing the bike and parts I'm "only" into it for a little over $1700. No way I can buy a bike with this many new parts for $1700 and I've had fun restoring an old dog back into a new pup.

The last pic is a couple days ago and I've yet to get the new tires mounted along with all of the new front end plastic. I'll be sure to post pics of the end result.













Looking good! Looks like the front brake cable is taking the short route on the first photo.
Junebug833
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Junebug833 3/23/2015 11:07am
3/23/2015 11:07am


I got the rest of graphics on the plastic! I'm getting anxious to get it finished I'm still waiting to get cylinder back from PowerSeal USA!
Premix
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Premix 3/23/2015 11:45am
3/23/2015 11:45am
You have a bitchin build going! Keep it up. I'm currently about 5 months into mine and still have to finish my motor.

Junebug833
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Junebug833 3/23/2015 11:49am
3/23/2015 11:49am
Thank you! Yours looks good Im going to do the same thing to my wheels too looks good brother!
reded
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reded 3/23/2015 12:10pm
3/23/2015 12:10pm
jmc2 wrote:
Looking good! Looks like the front brake cable is taking the short route on the first photo.
Not trying to steal Junebugs thunder but here is the end result minus the not yet received factory two tone seat cover.

Those with a savvy eye will pick up on the '02+ shrouds.







SlS257
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SlS257 3/24/2015 6:43am
3/24/2015 6:43am
Who did the graphics for your kx?
Markee
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Markee 3/24/2015 9:10am
3/24/2015 9:10am
SlS257 wrote:
Who did the graphics for your kx?
I had many sets done from Fusion Graphics, They are using a new vinyl that doesn't bubble, lays down awesome.
Junebug833
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Junebug833 3/24/2015 9:57am
3/24/2015 9:57am
SlS257 wrote:
Who did the graphics for your kx?
I am using Split Designs. I have always heard great things about the company so I received a sponsorship offer from them so I got my first kit for my 13 kx450 and it was amazing quality and very durable stuff i believe it 21mil thick stuff so it's really durable. They place of the metallic and hologram inlay's by hand and you can definitely tell. I had MGXUNLIMITED graphics on my 450 last year and as they looked good the quality of the graphic is no where near Split Designs. They also have excellent customer service and the turn around time is less than a week from the time of purchase. Call them and ask for Anthony.
Junebug833
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Junebug833 4/7/2015 3:28pm
4/7/2015 3:28pm


I got my pipe in yesterday! FMF Fatty and a friend of mine was trying to get rid of a FMF Shorty that conveniently for my bike for dirt cheap! Cylinder will be in tomorrow so should have her all done by tomorrow evening!

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