1990 KTM MX 250 Built

I just like the way the 93 looked better found 93 sx tank for it. Not too easy to come by. 

Did find this post that mentions for the wp 4054 fork bushings. Bushing part # GLYPG404420F ordered through a bearing house. 

Looking good I've just been doing part numbers comparing on the swingarm linkage steering stem bearings n such. 

That looks like it's the same up to 97. 

I'm going to also update the brakes on mine with a 93 94 front caliper. It's more like a modern dual piston. 

Along with the rear research shows up to 03 should fit. Using the caliper with the newer style carrier. 

Newer style rear master cylinders off current bikes also look like it will bolt right on. Got the idea from watching this video. 

Been reading that those older forks work better with a 7 weight fork oil instead of a 5 weight. Something to do with the fact the older forks having a more simple valving stack and less complicated oil flow. 

The thicker oil let's the valving work better vs the 5 weight. The 5 weight tends to blow through it faster. 

Just to follow up with I got a newer style rear caliper for my 91. It bolts right up to the frame bolt hole spacing is the same. 

I also got a front brake caliper and carrier from a 93 and it also bolts right up to the 4054 fork. Friend gave a newer style Nissan master cylinder like an 04 cr. 

I got the 2003 rear carrier and caliper mounted up. Not too difficult just have to grind down smaller the carrier slot on the swingarm.  I took away material from the bottom. And you have to grind down the stop a little bit. 

Everything fits up perfectly test fitted it with the wheel axle and rotor. 

Edit: I used a 03 SX rear setup which is the same as current stuff up to 22. 

I bought off eBay this parts unlimited Clutch cable was supposed to work on my 91. But it was too long so I had leftover from my 06 yz250 a Clutch cable. It fits and works perfectly with this asv Clutch perch.  Just a small gap around where it goes into the case nothing a lil bit of silicone won't fix. 

The early 1990s KTM250 and 300 had power valves that would eventually break and slide into the cylinder.

My understanding is that a 1994 power valve is the one to get, although some modification is required to get it to fit in with a 1990 cylinder.

There will be heaps of info about that on KTMtalk.com

I've got a 1990 KTM250e/xc that hasn't run since 1995 (the engine has been in pieces since then).

I don't have the skills to fix or restore the bike so I'm saving up to get someone else to do it.

From what I remember the PV drum is the same design as the current bike except it runs directly in the aluminium casting. The current design runs in ball bearings. The drum turning wears away the valve and the barrel casting and it will eventually move enough to touch the piston. We had to modify a later drum to fit a '93 300EXC where this had happened to a customer, I seem to remember it was a 2000 part.

The parts from my 91 power valve looks the same as the 94's minus the added stopper plate piece on the left side. That makes adjusting the power valve a little easier. 

The shaft on my 91 rides on bearings that came up as nla. Luckily cleaning them up worked. 

I found on ebay some brand of fork seals under brand name k & s for 4054 forks. Were inexpensive enough made in Taiwan. 

I did the fork and oil change on them myself really pretty easy. Didn't even need any special tools. I went with the maxima 7wt in it. 

Rear shock if you need a new shock bumper. The current gen 85's have 14mm shock shafts. I used one off a yz85. 

Is it possible to get in contact with you, I’m currently doing the same job, any help will be much appreciated 

Do you mean the clutch cover / water pump. I used one off a 95 those are alloy go right on. The 96/97 covers would work. If you drill out the blocked off hose cast area. 

Then you'll have to either thread the one side to screw in a new water spigot or press fit one in. Of your own.