My 2006 KX250 Build - Assembled!

Markopolo400
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Markopolo400 12/28/2015 8:21am
12/28/2015 8:21am
Phew, finally able to get this thing moving again after making it through Christmas. Crank is getting shipped off to get rebuilt, and decided to replace all the bearings in the transmission while I am in there.

Pics coming soon!
tobyedholm 12/28/2015 12:33pm
12/28/2015 12:33pm
Looks great! Following for sure.
T.Page
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T.Page 12/28/2015 6:36pm
12/28/2015 6:36pm
Like it allot.
T.Page
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T.Page 12/28/2015 7:44pm
12/28/2015 7:44pm

My 05. Like the kx's

The Shop

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zb658
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zb658 12/28/2015 7:54pm
12/28/2015 7:54pm

My current 05 project. These are bad ass animals we have here! I love mine. Ps. Mine is still in progress.
motofool
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motofool 12/29/2015 8:06pm
12/29/2015 8:06pm

I built my 05 In 2011, I love it!
Lucky13FIST
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Lucky13FIST 1/1/2016 9:39pm
1/1/2016 9:39pm
motofool wrote:
[img]https://p.vitalmx.com/photos/forums/2015/12/29/117318/s1200_IMG_20150606_010500.jpg[/img] I built my 05 In 2011, I love it!

I built my 05 In 2011, I love it!
That green frame is heavy duty! It looks so bitchin.
nascarnate326
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nascarnate326 1/2/2016 5:49am
1/2/2016 5:49am
Op what silencer are you going to use?
motofool
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motofool 1/2/2016 7:34pm
1/2/2016 7:34pm
motofool wrote:
[img]https://p.vitalmx.com/photos/forums/2015/12/29/117318/s1200_IMG_20150606_010500.jpg[/img] I built my 05 In 2011, I love it!

I built my 05 In 2011, I love it!
Lucky13FIST wrote:
That green frame is heavy duty! It looks so bitchin.
Thanks man I appreciate it!
BobPA
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BobPA 1/3/2016 7:13am
1/3/2016 7:13am
nascarnate326 wrote:
Op what silencer are you going to use?
For the price and look, he should consider this bad boy.

Markopolo400
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Markopolo400 1/3/2016 7:58am
1/3/2016 7:58am
nascarnate326 wrote:
Op what silencer are you going to use?
I was originally planning on re-furbing the R304 I had, but then PC started selling the R304 carbon which caught my attention, but the Bud is so much cheaper....Hmmmm
dbrunski125 1/3/2016 9:33am
1/3/2016 9:33am
nascarnate326 wrote:
Op what silencer are you going to use?
Markopolo400 wrote:
I was originally planning on re-furbing the R304 I had, but then PC started selling the R304 carbon which caught my attention, but the Bud is...
I was originally planning on re-furbing the R304 I had, but then PC started selling the R304 carbon which caught my attention, but the Bud is so much cheaper....Hmmmm
Pc carbon silencer would Def be the most trick. If only they made for rm 2 strokes lol
deltadestroyer11 1/3/2016 9:49am
1/3/2016 9:49am
zb658 wrote:
Well i'm thinking of running a different clamp offset as well. I hear the 21.5mm offsets are the magic set. Havent really gotten to ride the...
Well i'm thinking of running a different clamp offset as well. I hear the 21.5mm offsets are the magic set. Havent really gotten to ride the bike much since i bought it back in august of 15 due to suspension and my weight being conpletely opposite in settings. I'm a big boy. Lol
Yep the 21.5 and pro circuit link make that bike handle extremely good. Had that setup on my 05 and it was great. Just don't rais the forks over half an inch (yes half an inch) or the bike will headshake badly. 9-12 mm of raised fork tube height is about perfect.
Markopolo400
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Markopolo400 1/3/2016 9:55am
1/3/2016 9:55am
dbrunski125 wrote:
Pc carbon silencer would Def be the most trick. If only they made for rm 2 strokes lol
Well they do make them for KX 2-strokes Smile
Markopolo400
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Markopolo400 1/10/2016 4:51pm
1/10/2016 4:51pm
Been busy, but I have slowly been piecing together parts for the engine. Decided to replace all the tranny bearings while I had the cases apart, and get the crank rebuilt too.

Some pictures of the crank getting worked on by Andrew Cooksey



Got a new Wiseco Racer's choice piston (Lightweight, with a single TiN ring)


Tranny inspected, everything looked good with minimal wear for 100+ hours.


Finished rebuilt crank back on my bench, and the old rod which was still tight and looked good.



Cant wait to get the engine back together and in the frame. Gotta measure the cylinder next to see if it needs a replate, and tear down the power valve and clean it.
Markopolo400
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Markopolo400 1/25/2016 9:33am
1/25/2016 9:33am
Measured the cylinder at work on the CMM, still dead nuts in spec after all the hours of running. 32:1 Amsoil Dominator it's whole life Smile

Finally got the cases stripped of their bearings, got some cleaning to do and then can get the engine back together again.



I might get the award for slowest build lol. But I guess that comes with not having a heated garage in MN during the winter.
Markopolo400
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Markopolo400 1/31/2016 2:53pm
1/31/2016 2:53pm
Well, I finally made some progress and got all the bearings pressed into one case half. Started on the other and managed to wreck a case....Beyond pissed at myself.



I was pressing in a bearing and the lip it seats again is incredibly thin. One too many press pumps and bang and it broke off.





Currently weighing my options.

1. Run it as is

2. Buy an eBay case half, I found a couple but Kawi only sells them matched.

3. Bite the bullet and replace both case halves and all the bearings again and do everything the right way. This is what I am leaning towards.
Markopolo400
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Markopolo400 1/31/2016 7:06pm
1/31/2016 7:06pm
More pictures to get your guys opinions.




Pit Row

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garagedog 1/31/2016 7:43pm
1/31/2016 7:43pm
If you do it right, you will always have that piece of mind. The opposite is true also.
moto455va
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moto455va 1/31/2016 9:31pm
1/31/2016 9:31pm
I would definitely just replace it, I mean shit happens. Youre always gonna be thinking about that if you run it as is, and riding wont be nearly as enjoyable.
Hondas4Life3
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Hondas4Life3 2/1/2016 1:07pm
2/1/2016 1:07pm Edited Date/Time 2/1/2016 1:08pm
I agree with moto455 replace it and install new transmission bearings. In fear of doing the same thing I use the hot/cold method of installing bearings before going for the press.
731chopper
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731chopper 2/1/2016 1:18pm
2/1/2016 1:18pm
Ouch! I'm curious what you mean by your option of doing it the right way. Did you try to take a shortcut while pressing the bearing in?
project racer 2/1/2016 2:02pm
2/1/2016 2:02pm Edited Date/Time 2/1/2016 2:05pm
Freeze the bearings , heat the case. They will nearly drop in, with minimal encouragement from a soft drift. Press is over kill for work on fragile cases.

A skilled aluminum welder could fix those cases.
Markopolo400
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Markopolo400 2/1/2016 4:09pm
2/1/2016 4:09pm
What's frustrating to me is that this isn't my first go round. I have done the freeze/heat method for years, never had a problem. I bought a shop press this past summer, and I figured I would use it to make sure the bearing went in straight in addition to the freeze/heat.

The bummer is the Kawi bearing stop is paper thin, almost nothing to it, and the press punched right though it, completely my fault, which is what bothers me.

731chopper, by doing it the right way, I mean buy brand new matched cases and not mis match parts on eBay. I'm going to pay the idiot tax and suck it up. The good news is a set of KX250 cases is much cheaper than other OEMs.

The good news is this time I can put brand new cases in the oven without fear of pissing off the wife. Previous cases have been heated with a propane torch.
BobPA
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BobPA 2/1/2016 6:44pm
2/1/2016 6:44pm
Man up and buy the new cases. Sucks, but it is worth the piece of mind

I'm going to be selling perfect FMF gnarly and Pro circuit platinum expansion chambers soon if you are in need (I am buying the works Pro Circuit)
Markopolo400
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Markopolo400 2/1/2016 7:11pm
2/1/2016 7:11pm
BobPA wrote:
Man up and buy the new cases. Sucks, but it is worth the piece of mind I'm going to be selling perfect FMF gnarly and Pro...
Man up and buy the new cases. Sucks, but it is worth the piece of mind

I'm going to be selling perfect FMF gnarly and Pro circuit platinum expansion chambers soon if you are in need (I am buying the works Pro Circuit)
Yep thats the plan. They'll be ordered tonight or tomorrow, and a bunch of new bearings. Painful lesson but oh well.

I already have a brand new PC works pipe sitting on my bench for my KX Smile
Markee
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Markee 2/2/2016 7:06am
2/2/2016 7:06am
Another option is to use that bearing stop bolt, add a fabricated "extension" so that bearing stop, stops 2 bearings from drifting. Obviously if it wouldn't interfere with other parts.


jjheavychevy90 2/25/2016 1:36pm
2/25/2016 1:36pm
motofool wrote:
[img]https://p.vitalmx.com/photos/forums/2015/12/29/117318/s1200_IMG_20150606_010500.jpg[/img] I built my 05 In 2011, I love it!

I built my 05 In 2011, I love it!
Man that thing is drool worthy with that green frame, definitely has me thinking of going black shrouds rear fender amd number plates and a brighter green frame on my 01 kx
motofab36
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motofab36 2/25/2016 3:43pm
2/25/2016 3:43pm
Markopolo400 wrote:
What's frustrating to me is that this isn't my first go round. I have done the freeze/heat method for years, never had a problem. I bought...
What's frustrating to me is that this isn't my first go round. I have done the freeze/heat method for years, never had a problem. I bought a shop press this past summer, and I figured I would use it to make sure the bearing went in straight in addition to the freeze/heat.

The bummer is the Kawi bearing stop is paper thin, almost nothing to it, and the press punched right though it, completely my fault, which is what bothers me.

731chopper, by doing it the right way, I mean buy brand new matched cases and not mis match parts on eBay. I'm going to pay the idiot tax and suck it up. The good news is a set of KX250 cases is much cheaper than other OEMs.

The good news is this time I can put brand new cases in the oven without fear of pissing off the wife. Previous cases have been heated with a propane torch.
A heat gun also works nice to heat the cases. H F has them on sale sometimes for like $10
MxKing809
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MxKing809 2/25/2016 3:48pm
2/25/2016 3:48pm
BobPA wrote:
Man up and buy the new cases. Sucks, but it is worth the piece of mind I'm going to be selling perfect FMF gnarly and Pro...
Man up and buy the new cases. Sucks, but it is worth the piece of mind

I'm going to be selling perfect FMF gnarly and Pro circuit platinum expansion chambers soon if you are in need (I am buying the works Pro Circuit)
Markopolo400 wrote:
Yep thats the plan. They'll be ordered tonight or tomorrow, and a bunch of new bearings. Painful lesson but oh well. I already have a brand...
Yep thats the plan. They'll be ordered tonight or tomorrow, and a bunch of new bearings. Painful lesson but oh well.

I already have a brand new PC works pipe sitting on my bench for my KX Smile
When you get your cases, put the guide pins in, mate the two together and blend the seams. Polish the intake track and match the ports to your cylider. Most people will never have the opportunity to do all that with virgin cases without bearings to gum up!!

My CR had about 1/16th" overhang on the cylinder over the case, but since my bottom was together I could only modify the cylinder to match, as opposed to stuffing the crank to match the cylinder. If the cases had been split and new I would have stuffed them with epoxy and ground it down to match the cylinder.

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