Alright fellas, it's time to get a build thread going for the subject of my Mechanimation project, the 1993 KX250. Please be advised up front that this is going to be a long and slow moving project due how long it takes to animate the process the way I do. For those who haven't seen, this is what I'm referring to.
There is certainly no shortage of KX builds on Vital, but it seems that there is relatively little on the 92/93 bikes specifically. So I've assembled a bunch of info that I've found along the way as well as some of my thoughts and questions. Maybe this thread can be turned into a treasure trove of info on these bikes.
My vision going into this is to restore the bike to stock appearance in terms of frame color, graphics and seat cover. The 93's are considered by at least 3 or 4 people on the internet to be the best looking bikes ever made, and I wouldn't want to mess with a good thing. Blue hubs to match the forks is the only cosmetic change I'm really considering at this point.
Aside from that I'll probably go with vapor blasting of all the aluminum parts to make things pretty. Maybe a Boyesen clutch and ignition cover to spice things up a bit.
I welcome any input, ideas, and especially tech tips you may have relating to these bikes.
My first question is about the blue forks. I have yet to find any pics of them on a professional race bike from back in the day. Were they so bad that the pros didn't even use them or have I just not searched hard enough?
Notes on Suspension
• I'll be rebuilding and revalving the stock shock and forks with parts and Gold Valves from Race Tech. Fork uppers are currently out to be re-anodized, eager to see how the come out.
• Custom fork springs needed (only available in stock spring rate) Cannon Racecraft was widely recommended. Quoted $140 plus shipping
• Specs for fork spring free length: 514mm to 504mm. My spring length: 488mm. Is this amount of shrinking/compressing normal? I'll have them made to the proper spec, but I was surprised they were this far off.
Green Powder coat options
• What years did Kawi green/flow green change?
- Colorite #617 Lime Green is listed as a match for KX250 1990-1994 and 1999-2004, no match listed for 1995-1998. Was 95-98 a different color?
• From Kawasaki Flo Green? Thread (2018)
-Tiger brand powder coat "Fluorescent one-coat Green" Color 49/51340. Looks like a good match. Where to buy?
• From 1997 KX250 Retro Ripper Build! Thread (2017)
- Prismatic Powders PSS-5666 "Kiwi Green" Is also close. Can be bought from website. Leaning toward this as of now.
Options for swingarm paint.
From 1997 KX250 Restoration Thread (2014)
- 93/94 swingarm color is the same, changed in 95
- Duplicolor engine enamel looks to have a silver that matches well.
- Power plus paints Nickel and silver metallic were shown to be good matches for the swingarm. Power plus appears to be discontinued.
- Any suggestions for a powder coat that would match the 93 well?
- The swingarm is probably going to be replaced, due to a hole in the side. Is it worth trying to weld and refinish?

Replica Graphics.
• Both seem good and well reviewed. Evo-MX has OEM replica seat cover which I'll need, so I'm leaning that direction.
• Action Sports Decals: $199 for OEM replica Shrouds, swingarm, blank number plates backgrounds.
• Evo-MX: $170ish US (UK company) for shroud, swingarm, Blank number plate backgrounds, and seat.
Engine
• I'll be doing a full rebuild top and bottom.
• Cylinder definitely needs bored. It has a sleeve at stock bore so not an issue


- Only Wiseco makes oversized pistons for this bike.
- Would like stock bore Nikasil, probably not in budget.
- It appears the engine was ported at some point. Thoughts on the porting job? Looks a bit sloppy to my untrained eye.

• Option if power valves may be worn:
- Other Powervalves can be modified to work, according to 93/94 KX250 Obsolete Powervalve Option thread.
- Photos no longer available, maybe Kidkawie could repost them.
Clutch
• Starting to notch, will be replaced.
- Baskets available from several sources. Only Pro-X has inner hub and pressure plate


Brakes
• Many options for rotors and pads
• Galfer is the only brand I've found with braided brake lines for the 93. Any brands worth looking into for custom made at a reasonable price?
There are plenty of other things to cover, but I think this post is already plenty long. Thanks in advance for any info you can provide.
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