1994 KX250 Rebuild

Adama9x
Posts
26
Joined
2/26/2022
Location
AU
Edited Date/Time 10/2/2026 1:11am

A friend of mine had one of these new. I can still remember riding it thinking how good it was.

Fast forward 30 odd years(holy crap I’m old) one popped up for sale which the owner had thrown a lot of money at.

I thought I could save myself a lot of time and money by buying one that was running and half ok.🤣🤣What an idiot.

After one ride I ended up stripping the whole bike apart to fix other people’s crap repairs.

Please come on a journey into the unknown.🤣IMG 8518 3

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Nairb#70
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4325
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2/25/2020
Location
Ivoryton, CT, USA
10/2/2026 3:29am

Bike looks to be low hours and in excellent condition.

1
Adama9x
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26
Joined
2/26/2022
Location
AU
10/8/2026 12:39am

The very first lap on the track I had a massive flashback in time,so many good memories with mates back in the 90s on 2 strokes.

A few issues came up pretty quickly. The brakes are terrible, the forks are so soft they would compress and not rebound under brakes,at the end of the day they were leaking. I could feel a bit of backlash through the kickstarter/clutch.

The motor has a great hit of the bottom and snappy midrange it definitely doesn’t have the top end/over rev of a 90s Honda.

Regardless of the problems I still had an absolute blast.

Adama9x
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2/26/2022
Location
AU
10/8/2026 12:48am

After doing some more research on this model. I got in touch with another forum member called Kidkawie who restored one of these back to like new.

He gave me a lot of information on what to look for particularly cracks in the frame.

I checked out the backlash issue with the engine and the primary gear was so sloppy it was moving backwards and forwards plus sideways. The previous owner used a aftermarket crank and the machining tolerances are garbage.

 

Adama9x
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2/26/2022
Location
AU
10/8/2026 12:56am

Pulled the motor out looked for cracks and yes.Both lower engine mounts cracked,footpeg mounts cracked.Previous owner cut through the lower linkage bolt(must have been seized) and cut into the frame so the lower linkage was sloppy.Subframe also cracked,the powder coating hid all of this.Just Awesome work.

2

The Shop

Adama9x
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26
Joined
2/26/2022
Location
AU
10/8/2026 1:08am

So after one ride I completely stripped the bike.410AACC9-329F-4A76-9429-9A4920A9EE40.jpeg?VersionId=T0HzOBOUGK1cOZvZeejmZtzq7G0FCA7BF0-25D6-442C-AFE8-84248793516A.jpeg?VersionId=vwiE16EtRvEFOV.xZnM.nXq13fPQExPA969D765-CECA-4D04-B90E-3BE5A79F2CC48633343B-8C27-41BF-8D85-A07DC37FC11C8D84A8EC-5719-4090-AD34-249B9E2157F8.jpeg?VersionId=Cab532e2CfZGnIyAgQgR.saf3jI

1
Nairb#70
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4325
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Location
Ivoryton, CT, USA
10/8/2026 5:13am
Nairb#70 wrote:

Bike looks to be low hours and in excellent condition.

Well I guess looks can be deceiving. Welds by Frankenstein? A bunch of paint to make it what it aint.

10/8/2026 5:16am
Adama9x wrote:
So after one ride I completely stripped the bike.

So after one ride I completely stripped the bike.410AACC9-329F-4A76-9429-9A4920A9EE40.jpeg?VersionId=T0HzOBOUGK1cOZvZeejmZtzq7G0FCA7BF0-25D6-442C-AFE8-84248793516A.jpeg?VersionId=vwiE16EtRvEFOV.xZnM.nXq13fPQExPA969D765-CECA-4D04-B90E-3BE5A79F2CC48633343B-8C27-41BF-8D85-A07DC37FC11C8D84A8EC-5719-4090-AD34-249B9E2157F8.jpeg?VersionId=Cab532e2CfZGnIyAgQgR.saf3jI

If you've never welded before, you might be able to do a better job than the previous owner!

2
profmur
Posts
196
Joined
3/13/2024
Location
Somewhere, NJ, USA
10/8/2026 5:30am
Adama9x wrote:
So after one ride I completely stripped the bike.

So after one ride I completely stripped the bike.410AACC9-329F-4A76-9429-9A4920A9EE40.jpeg?VersionId=T0HzOBOUGK1cOZvZeejmZtzq7G0FCA7BF0-25D6-442C-AFE8-84248793516A.jpeg?VersionId=vwiE16EtRvEFOV.xZnM.nXq13fPQExPA969D765-CECA-4D04-B90E-3BE5A79F2CC48633343B-8C27-41BF-8D85-A07DC37FC11C8D84A8EC-5719-4090-AD34-249B9E2157F8.jpeg?VersionId=Cab532e2CfZGnIyAgQgR.saf3jI

Is that stick welding?

Adama9x
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26
Joined
2/26/2022
Location
AU
10/8/2026 10:34pm

I have a mig at home but not a tig and the frame needs both.One of my friends has a race car fabrication business with everything which is lucky for me.The main issue was fixing the frame at linkage pivot.I spent hours grinding and file finishing it flat before welding in thick washers to get the frame back where the linage bearing sleeve was tight.You can see the gap after the previous owner cut into the frame.099F7A73-F21E-46A6-96BB-DC0856FB6964792D5704-9C6D-43C1-86B9-FC70B9A4B56F

2
Adama9x
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2/26/2022
Location
AU
10/8/2026 10:36pm
ACB1155F-4485-4BB0-A386-2A62D64F09C9
3
Adama9x
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Joined
2/26/2022
Location
AU
10/8/2026 10:38pm

The frame was welded up everywhere.7533353C-DB09-46BA-8D1E-D8476E56BDF3F02BCB83-62BA-4AEE-A832-127CC3CF5FF1.jpeg?VersionId=oGvbt1 6rwID7UGYtpv1FBcRCo2F0B2582-4940-4A03-AA4B-F008CA5995DFE132724E-C1CD-4891-BD37-358B42FED34FA6F175D7-6652-46EC-BEB8-4874773860DD

3
Adama9x
Posts
26
Joined
2/26/2022
Location
AU
10/8/2026 10:44pm

I dummy fitted the suspension and made sure everything was good.D6C630FE-E50B-45D5-9D2E-881F5199AE98.jpeg?VersionId=N5q8FE7DFE3B6-48BF-4802-BE24-E2AC8D12C6B9.jpeg?VersionId=pKBnVg7dPfqbB.kNtu3Qb8C8n9wWw7FE7BB0B-A303-4492-B4E6-E8D9D957DF92.jpeg?VersionId=UEIm2DHJ

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Adama9x
Posts
26
Joined
2/26/2022
Location
AU
10/14/2026 4:08am

I got paint matched up closer to the UFO plastics,so the colour is a bit more vibrant than oem green.4CC7D7A5-D6DB-4EC8-8CB4-95B6A925A5195EA5136C-934E-4380-BE55-AC27C802625F.jpeg?VersionId=Or5Ka1KPzlZvOe2CE706B1-A5C6-4923-911E-9965B8D2E855

6
Wycked31
Posts
495
Joined
3/25/2014
Location
West Palm Beach, FL, USA
10/16/2026 11:18am

Looks great. Kewi green is a great match too.

10/16/2026 1:47pm
Adama9x wrote:
I dummy fitted the suspension and made sure everything was good.

I dummy fitted the suspension and made sure everything was good.D6C630FE-E50B-45D5-9D2E-881F5199AE98.jpeg?VersionId=N5q8FE7DFE3B6-48BF-4802-BE24-E2AC8D12C6B9.jpeg?VersionId=pKBnVg7dPfqbB.kNtu3Qb8C8n9wWw7FE7BB0B-A303-4492-B4E6-E8D9D957DF92.jpeg?VersionId=UEIm2DHJ

Cool Project 👍 

How did you clean up the Swingarm? Is it Aqua Blasted ?

Adama9x
Posts
26
Joined
2/26/2022
Location
AU
10/16/2026 10:43pm
Adama9x wrote:
I dummy fitted the suspension and made sure everything was good.

I dummy fitted the suspension and made sure everything was good.D6C630FE-E50B-45D5-9D2E-881F5199AE98.jpeg?VersionId=N5q8FE7DFE3B6-48BF-4802-BE24-E2AC8D12C6B9.jpeg?VersionId=pKBnVg7dPfqbB.kNtu3Qb8C8n9wWw7FE7BB0B-A303-4492-B4E6-E8D9D957DF92.jpeg?VersionId=UEIm2DHJ

Cool Project 👍 

How did you clean up the Swingarm? Is it Aqua Blasted ?

Thanks,the previous owner had it powder coated.

1

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