1987 Kawasaki KX250 low-key restore

Got some new reproduction plastic, reproduction OEM graphics, Sudco PWK38 air striker knockoff, new air filter and some other odds and ends:

Clutch cover had a crack. Thought about tigging it but went with a thorough cleaning and JB weld. low-key resto, yo.

few random pics:





Got some 1988 KX forks pretty cheap off Ebay. These have cartridge internals unlike the 87 units.

Bike had very low compression when I got it. It ran but I could literally turn it over with my hand.

Found a sweet deal on a newly replated 87 cylinder and head ($150) and got a NOS Wiseco piston for $70.

I pulled powervalves from the old cylinder, cleaned them up real good and installed in the new cylinder.

Should be installing this on the engine soon, then I'll pull the engine, clean and paint black.

Piston and cylinder installed tonight. Thoroughly cleaned powervalves and replaced all seals before re-installing.

Next, gonna remove the engine and strip frame to clean and at least rattle can with identical OEM colors.

Got the engine out and frame stripped down. Been cleaning gunky smaller parts today.

Before:


After

Found time to get the frame and swingarm power washed. Not super thrilled with just a rattle can paint job - the frame rails has a lot of little nicks and scratches that will probably show through with spray paint.

Probably gonna drop it off at Miller's in Lilburn for powder coating. Same with swingarm and subframe.

The wheels on this bike are just gonna have to suck. Found a rear wheel replacement though the spoke nipples are pretty rusty. The front rim is stained with red clay and I couldn't get that shit off even with a good soak with purple power. Can't justify dropping 800 in wheels even if I could find someone to make up a set (probably unlikely) and don't want to fuck with lacing new rims. Low key resto, yo.

fuck it, dropped the frame and swingarm off at the powder coaters.

nevermind the boots, they will be replaced with swipers per 87 oem.

Anyone happen to have leads on stiffer fork springs for 1988 KX250/500 forks? Racetech checked and have nothing not even close. 88's were one off forks, they got cartridge internals. 87 were standard. 89s of course had the amazing 46mm forks.

Unfortunately I have already way overspent this build including getting the '88 forks (at the time I was not able to locate a full set of 89 46mm forks + triples for a reasonable price). So swapping to yet another set is not an option for me. Maybe the next owner can do that.

Hoping someone can assist or give some leads on 88 KX springs. Progressive lists some, but they show them for a zillion 80s models forks. Per their specs their springs will be too large (OD) for these 88 cartridge forks.

Did more research, the XR400R fork is 43mm cartridge. It uses a 470mm x 36mm OD spring,

The 88 KX250 has 549mm x 35.9mm OD.


Could probably make the XR400R springs work with a simple 80mm PVC spacer. RT sells the XR400R springs at 129 + ship.

KDXGarage learned me on the '88 KX triple clamps today. The 125 (the clamp I bought as a "KX250" clamp) has the one piece handlebar/clamp design. Same year KX250/500 has a separate bolt on handlebar clamp. Rake/trail differs between the 125 and 250 as well.

Found a cheap and clean KX250 clamp on ebay and waiting for that to arrive now. Will need to move my new stem bearings over or maybe just get new stem bearings and sell the 125 clamp as restored.

Just saving this one from becoming White Claw cans. Not much more than that. Parts are next to impossible to locate for this one-year generation KX250.

Not good


Boyesen still makes a RAD valve for the '87 KX250


Waiting on a fork rod holder to arrive, then complete fork restoration (new bushings, seals, stiffer springs and 5wt oil). She's not much to look at, but will eventually make someone a nice vintage racer

I'm really smart and misplaced the head stays when I took the bike apart 2 years ago.

Anyone happen to have a set laying around?

Finally sourced a decent pipe