1996 KX250 project done!

RyanLester761
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1128
Joined
2/7/2007
Location
El Dorado Hills, CA, USA
Here's my third rebuild/restoration, after the 1995 Ryan Hughes replica Splitfire KX125 and the 1993 Jeff Emig replica YZ125.

This KX250 had a running engine, although it was purchased as a basket case from my buddy who owned the local bike shop. He was nice enough to weld the footpeg mounts and get the frame sand blasted for me before I picked it up. The rest was up to me. There was some extensive parts sourcing since I was missing several small parts.

I found the purple plastics and original graphics over time. Along with a Pro Circuit pipe and silencer, Boyesen Rad valve, Tecnosel seat cover and purple Renthal bar pad. I had the PC pullrods already so I threw them on for fun.

I didn't take pictures until later in the build but here's some randoms of the progress...in very random order.
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The Shop

bradpr32
Posts
218
Joined
9/24/2015
Location
AU
7/5/2016 1:29am
so good
@lips395
Posts
375
Joined
1/20/2016
Location
AU
7/5/2016 2:05am
wow that is so nice ! i would love to have a original 1996 kx250 like that one day. great job thanks for sharing
Schwanz22
Posts
329
Joined
1/13/2014
Location
Roanoke, TX, USA
7/5/2016 2:21am
Sweet!!! Great job man!
7/5/2016 2:37am
That looks nice. My first race bike was a 1996 kx 60. I've been on the look out for a 96 kx125. I love the purple monsters
MCfan4life
Posts
5731
Joined
6/25/2009
Location
Qld, AU
7/5/2016 5:06am
Awesome work again Ryan!

Boyesen can actually still supply these stickers!! I emailed them and they sent me a few free of charge for my 95 HoT Wink



RyanLester761
Posts
1128
Joined
2/7/2007
Location
El Dorado Hills, CA, USA
7/5/2016 9:43am
Here's my third rebuild/restoration, after the 1995 Ryan Hughes replica Splitfire KX125 and the 1993 Jeff Emig replica YZ125. This KX250 had a running engine, although...
Here's my third rebuild/restoration, after the 1995 Ryan Hughes replica Splitfire KX125 and the 1993 Jeff Emig replica YZ125.

This KX250 had a running engine, although it was purchased as a basket case from my buddy who owned the local bike shop. He was nice enough to weld the footpeg mounts and get the frame sand blasted for me before I picked it up. The rest was up to me. There was some extensive parts sourcing since I was missing several small parts.

I found the purple plastics and original graphics over time. Along with a Pro Circuit pipe and silencer, Boyesen Rad valve, Tecnosel seat cover and purple Renthal bar pad. I had the PC pullrods already so I threw them on for fun.

I didn't take pictures until later in the build but here's some randoms of the progress...in very random order.
Good to know. I will email them. Thanks for the tip!
Kidkawie
Posts
1191
Joined
8/31/2012
Location
ქუთაისი, GE
7/5/2016 11:15am
I like the addition of a few period parts. Clean build man!
RyanLester761
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1128
Joined
2/7/2007
Location
El Dorado Hills, CA, USA
7/5/2016 11:48am
Thanks Jay. Yeah, this is what I would have added if I had the bike back in the day. Some tasteful bolt-ons.
sandman768
Posts
8185
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3/21/2014
Location
Saratoga Springs, NY, USA
7/5/2016 12:09pm
Very well done! Very clean ...nice job on the pipe......even have the correct carb vent hoses...Brand new airbox?
sands-cr250
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111
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3/24/2016
Location
Edwardsville, IL, USA
7/5/2016 12:22pm
Looks rad!
7/5/2016 3:38pm
Did you get that silencer from me? If it's the one we traded, it looks awesome Smile
RyanLester761
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1128
Joined
2/7/2007
Location
El Dorado Hills, CA, USA
7/5/2016 3:44pm
sandman768 wrote:
Very well done! Very clean ...nice job on the pipe......even have the correct carb vent hoses...Brand new airbox?
Thanks! Yes, I replaced the carb air hoses. Those old ones get so brittle and discolored, as you know.

The airbox was used. I completely disassembled it and cleaned it up like new.
RyanLester761
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1128
Joined
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Location
El Dorado Hills, CA, USA
7/5/2016 3:46pm
Did you get that silencer from me? If it's the one we traded, it looks awesome Smile
Hi Jeff. I think that silencer I got from you sold with the 2000 kx250 I had.
7/6/2016 8:39am
Hi Jeff. I think that silencer I got from you sold with the 2000 kx250 I had.
I sold my kx also lol.
RyanLester761
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1128
Joined
2/7/2007
Location
El Dorado Hills, CA, USA
7/6/2016 8:55am
I sold my kx also lol.
Oh man, after all that tinkering?! Haha. What a bummer. What's your latest project?
MaxPower
Posts
2701
Joined
8/15/2006
Location
USA
7/6/2016 7:33pm
That could not have come out any better than it did.
Good job.
7/6/2016 11:00pm
Oh man, after all that tinkering?! Haha. What a bummer. What's your latest project?
probably a new ktm or husky 300 if my back gets better. Someone rear ended us last year and messed up 2 more discs in my back and one in my wife's neck. I rode the kx one day last month and was in the emergency room that night lol. Couldn't walk because my legs were locked up from disc pressure on my nerve. I sold it three days later lol.
7/7/2016 4:24am
bike looks fantastic , I'm a sucker for the oem purple too , reminds me of the good old days when we where a lot younger lol
Micahdogg
Posts
1263
Joined
1/3/2011
Location
USA
7/7/2016 2:38pm
Holy smokes, super fine job on that one! You guys kill me the level of detail you pull off.
RF145
Posts
503
Joined
5/31/2013
Location
Rutherford, NJ, USA
7/7/2016 3:10pm
probably a new ktm or husky 300 if my back gets better. Someone rear ended us last year and messed up 2 more discs in my...
probably a new ktm or husky 300 if my back gets better. Someone rear ended us last year and messed up 2 more discs in my back and one in my wife's neck. I rode the kx one day last month and was in the emergency room that night lol. Couldn't walk because my legs were locked up from disc pressure on my nerve. I sold it three days later lol.
Ace, I was first rear ended in 2010, then again in 2014. I went to the ER three times, 2010, one year to the day in 2011 and in 2014. My back was screwed up and riding/racing was a thing of the past. I saw doctor after doctor and although I have bulging and herniated discs from both accidents, there was no operation to stop the pain according to the doctors. I did have three epidurals though, again in 2010/2011/2014 with the last one just a month before I was rear ended again.
In 2015 though, I saw a new doctor and he injected directly into my back muscles, which have been in spasm for 5 years, a cocktail of cortisone and steroids that have allowed me to ride again. I still have much work to do as far as getting the core strength back due to five years of laying in bed.........but it was a corner I had been looking to turn for a long, long time.
I visited so many doctors over the last six years that I added MD to the end of my name. I also tried very form of eastern medicine too.
Hopefully you will find the right doctor to help you overcome this life changing issue. Good luck.
RyanLester761
Posts
1128
Joined
2/7/2007
Location
El Dorado Hills, CA, USA
7/7/2016 3:23pm
probably a new ktm or husky 300 if my back gets better. Someone rear ended us last year and messed up 2 more discs in my...
probably a new ktm or husky 300 if my back gets better. Someone rear ended us last year and messed up 2 more discs in my back and one in my wife's neck. I rode the kx one day last month and was in the emergency room that night lol. Couldn't walk because my legs were locked up from disc pressure on my nerve. I sold it three days later lol.
RF145 wrote:
Ace, I was first rear ended in 2010, then again in 2014. I went to the ER three times, 2010, one year to the day in...
Ace, I was first rear ended in 2010, then again in 2014. I went to the ER three times, 2010, one year to the day in 2011 and in 2014. My back was screwed up and riding/racing was a thing of the past. I saw doctor after doctor and although I have bulging and herniated discs from both accidents, there was no operation to stop the pain according to the doctors. I did have three epidurals though, again in 2010/2011/2014 with the last one just a month before I was rear ended again.
In 2015 though, I saw a new doctor and he injected directly into my back muscles, which have been in spasm for 5 years, a cocktail of cortisone and steroids that have allowed me to ride again. I still have much work to do as far as getting the core strength back due to five years of laying in bed.........but it was a corner I had been looking to turn for a long, long time.
I visited so many doctors over the last six years that I added MD to the end of my name. I also tried very form of eastern medicine too.
Hopefully you will find the right doctor to help you overcome this life changing issue. Good luck.
That's great news! I hate to see you guys hang it up do to an injury... especially a non-moto related injury. I'm glad you found some relief and I hope Jeff (Ace) all the luck as well.

Thanks for chiming in, guys!

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