1989 kx 250 tear down / build finished! I"m a Tool...

Glen
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Glen 2/26/2016 3:26pm
2/26/2016 3:26pm
Glen wrote:
for the powervalves and anything with a lot of carbon, get a gallon of berryman's chem-dip carb cleaner. Throw the parts in for a few days...
for the powervalves and anything with a lot of carbon, get a gallon of berryman's chem-dip carb cleaner. Throw the parts in for a few days and you will literally be able to wash them off with water and they'll look brand-new.
sandman768 wrote:
I have 2, 1 gallon pales I use for my carbs, right under my parts washer! Did not even think to use them! Heading to the...
I have 2, 1 gallon pales I use for my carbs, right under my parts washer! Did not even think to use them! Heading to the garage to drop the main valve in the can! Thanks! They work great on the carbs too!
Awesome so far! I would love to have an '88/'89 KX250. So how did you make out the power valves? I see the cylinder is together, so I'm hoping it went well?
sandman768
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sandman768 2/26/2016 6:28pm
2/26/2016 6:28pm
Glen wrote:
for the powervalves and anything with a lot of carbon, get a gallon of berryman's chem-dip carb cleaner. Throw the parts in for a few days...
for the powervalves and anything with a lot of carbon, get a gallon of berryman's chem-dip carb cleaner. Throw the parts in for a few days and you will literally be able to wash them off with water and they'll look brand-new.
sandman768 wrote:
I have 2, 1 gallon pales I use for my carbs, right under my parts washer! Did not even think to use them! Heading to the...
I have 2, 1 gallon pales I use for my carbs, right under my parts washer! Did not even think to use them! Heading to the garage to drop the main valve in the can! Thanks! They work great on the carbs too!
Glen wrote:
Awesome so far! I would love to have an '88/'89 KX250. So how did you make out the power valves? I see the cylinder is together...
Awesome so far! I would love to have an '88/'89 KX250. So how did you make out the power valves? I see the cylinder is together, so I'm hoping it went well?
No big deal with the valves, they have some normal wear on the channels that connect the center valve, this creates a little play in the center "flap" valve, but still function fine, I always want to replace any wear items with new when rebuilding, but sometimes the parts are just not availible. If this were to be my main bike, I would bring these valves to a machine shop & have them made out of a stronger metal than aluminum. I will run it as is & continue looking for nos valves, but, these valves are 88-89 250 only & appear to be long used up! I knew that going into this, that's why I, at least made sure I bought a running bike to start with. For the 6-10 hrs I will likely ride this bike, they will be fine. I had this bike brand new back in 89 when I was just getting serious into racing, great bike, no issues at all, never let me down, magazines said it was mellow, but I pulled my fair share of "B " class holeshots.
sandman768
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sandman768 2/29/2016 6:28pm
2/29/2016 6:28pm


Finished up the last of the glass beading, I hope!



Frame back from sandblast shop, I asked them not to blast the entire frame, as most of the original paint was still good, looks like a full frame refinish now...I need to test fit some parts before having welds chased on lower cradle. I will also make & weld on a skid plate to bottom of the frame, I have noticed a lot of late 80"s early 90"s factory bikes had welded skid plates.

Pipe blasted also, looks much better, still need to get dents blown out, then sand & blue welds

That's it for a while, time to do some riding down in Fla!
Bryan_Wanke
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Bryan_Wanke 3/1/2016 8:06pm
3/1/2016 8:06pm
Sandman, I work at a MX shop here in MI. Let me look in the back tomorrow for a PC works pipe. I know we have alot of old stuff.

The Shop

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sandman768
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sandman768 3/2/2016 4:55am
3/2/2016 4:55am
Bryan_Wanke wrote:
Sandman, I work at a MX shop here in MI. Let me look in the back tomorrow for a PC works pipe. I know we have...
Sandman, I work at a MX shop here in MI. Let me look in the back tomorrow for a PC works pipe. I know we have alot of old stuff.
Awesome, thanks for taking a look!
Bryan_Wanke
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Bryan_Wanke 3/2/2016 9:25am
3/2/2016 9:25am
No luck on the 89 works pipe. We do have a 90 kx250 raw pipe but it's a bills pipe. And we also have a platinum pic 89 kx250 pipe
sandman768
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sandman768 3/7/2016 2:27pm
3/7/2016 2:27pm
Bryan_Wanke wrote:
No luck on the 89 works pipe. We do have a 90 kx250 raw pipe but it's a bills pipe. And we also have a platinum...
No luck on the 89 works pipe. We do have a 90 kx250 raw pipe but it's a bills pipe. And we also have a platinum pic 89 kx250 pipe
Bryan, sent you a pm about the pc platinum pipe, let me know what you have to get for the pipe... Thanks
sandman768
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sandman768 3/11/2016 11:34am
3/11/2016 11:34am




Nos rear pedal, Ti spring..
sandman768
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sandman768 3/11/2016 11:44am
3/11/2016 11:44am




Works connection Kx 500 frame guards fit with minimal modification to left side guard, rt side bolts right on.

Made mockup of skid plate to be welded into lower frame cradle. Have foot pegs fitted, but need to to have welder build up bottom of peg brcts & replace rear brake pedal post.
Bryan_Wanke
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Bryan_Wanke 3/11/2016 8:44pm
3/11/2016 8:44pm
Hey man, just saw the post. Ill look monday at the price. Wheres it getting shipped to?
sandman768
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sandman768 3/14/2016 10:00am
3/14/2016 10:00am


Evo -MX continues to impress with very high quality products!
moto543
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moto543 3/15/2016 7:50pm
3/15/2016 7:50pm
I had an '89 and LOVED it! Thanks for sharing your build!
sandman768
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sandman768 3/16/2016 2:15pm
3/16/2016 2:15pm
moto543 wrote:
I had an '89 and LOVED it! Thanks for sharing your build!
Thanks moto543, the builds on Vital have inspired me...fitted newer Pro circuit kx pegs, rebuilt peg mounts with weld. Made a skid plate out of 20 gauge steel, going to have the weld shop chase lower cradle/ engine mount welds, weld skid plate in & replace my rear brake pivot mount.









sandman768
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sandman768 3/31/2016 9:40am
3/31/2016 9:40am












Had a few stripped out bolt holes repaired, new rear brake pedal mount, lower engine mounts rewelded & skid plate welded. Had to mount up engine cases to line up oil drain bolt & drill hole for access. Mounted number plate back grounds & radiator shroud decals. Frame off to powdercoater tomaro. Still waiting on plater to do my batch of hardware, may stop in at platers shop tomaro with some coffee & donuts to like a fire under their ass...
Jeremy200
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Jeremy200 4/2/2016 7:36pm
4/2/2016 7:36pm
looking good. looking forward to seeing it all powder coated. That bash plate will look very "factory" powder coated.
sandman768
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sandman768 4/3/2016 11:12am
4/3/2016 11:12am
Jeremy200 wrote:
looking good. looking forward to seeing it all powder coated. That bash plate will look very "factory" powder coated.
Thanks, It"s fun when everything is done & reassembly can begin. At this point my plating vendor is holding me up, sometimes he is quick, sometimes I need to visit him with coffee & donuts...
sandman768
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sandman768 4/6/2016 12:55pm
4/6/2016 12:55pm



Factory swingarm color was lighter than what I"m using, wanted a closer match to the Ti spring, went with the look of the later 90"s kx grey. We"ll see how it looks against the powdercoated frame before I apply the arm decals.
sandman768
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sandman768 4/14/2016 10:04am
4/14/2016 10:04am




Box of Joe & dozen donuts always works! Had some of my 82 RM 250 hardware plated also, I"ll put that together while I wait for frame back from PowderTech. Now I can reassemble a lot of sub assemblies while I wait for the frame.

Pit Row

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sandman768
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sandman768 4/14/2016 10:32am
4/14/2016 10:32am
Been on the lookout for another set of kips valves as mine are pretty worn causing the center flapper valve to be loose & sloppy. While surfing Craigslist I came across Biccum motor sports in Ca. Parting an 89. After convincing him I"m for real, he sold me the complete cyl. With all the kips valves for a great price! Thanks Biccum Motorsports! The valves are in much better condition than mine, I have them soaking in carb cleaner before I glass bead them.
sandman768
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sandman768 4/23/2016 6:33pm
4/23/2016 6:33pm
















Frame back from powdercoater. Put a few hrs into it today...
sandman768
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sandman768 4/23/2016 6:35pm
4/23/2016 6:35pm


sandman768
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sandman768 4/23/2016 6:43pm
4/23/2016 6:43pm
Going to focus on rolling chassis before I get motor back together. Forks are out getting rebuilt, I"ll have tires mounted up on wheels by the time the forks are done. My brothers rg 500 forks also being rebuilt, soon as he gets his forks back we can get his Rg off my lift! Taking my time & really enjoying the reassembly of the KX.
sandman768
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sandman768 5/3/2016 4:57am
5/3/2016 4:57am








Airbox 101..….who knows how long the p.o. Was sucking dirt at the cage to boot junction, like most late 80"s & 90"s bikes did. I remember disassembling every airbox back then to silicone the airbox to boot. Gave the box the carbon fiber look. Front wheel built, new tusk rotor.
sandman768
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sandman768 5/13/2016 4:46am
5/13/2016 4:46am








Pretty much as far as I can go without the forks.....once I get a roller I can focus on the engine, I did swap out the original power valve parts with the better set I found, needless to say, I can swap out & setup these Kip's valves pretty fast now.
chuckie108
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chuckie108 5/13/2016 8:36am
5/13/2016 8:36am
Awesome Build so far! '88 and '89 KX's are high on my list of bikes I want to build, love them for some reason.
sandman768
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sandman768 5/15/2016 4:34pm
5/15/2016 4:34pm
chuckie108 wrote:
Awesome Build so far! '88 and '89 KX's are high on my list of bikes I want to build, love them for some reason.
Thanks chuckie108, I had been looking for an 89 250 for a long time, they do not pop up to often in my area. that's why I bought this one, Full well knowing it needed a lot of love, I enjoy these restores but they are a lot of work! I like the 88-89 kx"s too, I had & raced 89,90 &91 kx"s back when they were new, but only really wanted the 89 to do over. The 90 & 91"s come up for sale often, must have sold more of those years.
sandman768
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sandman768 5/19/2016 12:05pm
5/19/2016 12:05pm
mock up.....while still waiting on my forks....pretty happy with the pipe, it was pretty hammered....





Micahdogg
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Micahdogg 5/19/2016 12:51pm
5/19/2016 12:51pm
Looks really good. I missed it but did you paint the swingarm or is that powder?
sandman768
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sandman768 5/19/2016 1:31pm
5/19/2016 1:31pm
Micahdogg wrote:
Looks really good. I missed it but did you paint the swingarm or is that powder?
I painted the arm, same as the triples, pegs. Slightly darker than the original grey they used that year. Maybe from 95-97 kx. Looks like Titanium...I did have the frame, clutch & water pump covers powdercoated, thought about hubs, but just left them raw. Every time I do a build I end up doing something a little different, I try to do what I can to keep cost somewhat reasonable.
Bill Elliott
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Bill Elliott 5/20/2016 4:57pm
5/20/2016 4:57pm Edited Date/Time 5/20/2016 6:46pm
I'm new to this site so be patient. I've been out of motocross for several years. I rolled over the other morning and turned on facebook and a 1989 KX250 was looking me in the face. I got excited because my last real year of racing was in 1989 and I was racing my 88 KX250. I was young and had my first child in April of 89. Bradley was sick but we didn't know how sick. I quit racing shortly after to spend all the time I could with him before he died in September. This bike stuck out like a sore thumb and I stole it for $400. I didn't really know what I had until I got it home. It was advertised as a 91 model. I ran the vin and it was an 89. I've never done a full restore and have a good product to work with. The tear down is complete and the only problem it looks like I may run into is the center KIPS valve is broken and as you know it's no longer made. Any help on finding one? I'm cruising ebay and all the other sites I know about. I usually slap a name to my bikes and this restore will be dubbed "Bradley Ray" in memory of my son. Thanks for any info you may have. Your bike looks A-1 friend.

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