Posts
31
Joined
3/2/2022
Location
CA
US
Edited Date/Time
8/4/2022 5:19pm
In February I picked up an abused 95 KX250 to restore. I hope to finish it within a few weeks. Here's my progress so far...
What it looked like when I picked it up:
It doesn't look horrible from the pictures. But when I started digging in there were many surprises. It was missing a front caliper (I already knew this). The wheels were destroyed (esp the front). The right side cover and clutch cover were broken from previous owner using the wrong kick starter (i knew this too). The swingarm bearings were so shot that the swingarm was actually rubbing against the engine cases (i did not know this!). The inside of the pipe and the powevalve assembly were encrusted with carbon. But overall it had a solid foundation for a restoration. The frame and engine were in relatively decent condition.
So far I've built new wheels, rebuilt the swingarm, rebuilt the engine (had oem crank rebuilt, replated cylinder, new powervalve gears, new clutch and outer basket, oem bearings, etc..). Here's some eye candy:
Next week I should have the suspension finished, and will also hopefully have the frame back from the powdercoater. Then I'll be rebuilding the brakes and cleaning various parts. I also found a 97 oem pipe in really good condition which I'm going to try to remove a small dent from and repaint.
Originally I wanted to build a 97-style Splitfire bike. But after coming across a photo of a 92 KX with blue wheels my jaw dropped and I decided to go for the early 90s green and blue look. The frame is being done in flo green to match the flo green plastics I got. And I'm still unsure about the graphics.
I'm documenting as much of this build as I can in short time lapsed videos for those who are interested. Let me know what you guys think so far!
What it looked like when I picked it up:
It doesn't look horrible from the pictures. But when I started digging in there were many surprises. It was missing a front caliper (I already knew this). The wheels were destroyed (esp the front). The right side cover and clutch cover were broken from previous owner using the wrong kick starter (i knew this too). The swingarm bearings were so shot that the swingarm was actually rubbing against the engine cases (i did not know this!). The inside of the pipe and the powevalve assembly were encrusted with carbon. But overall it had a solid foundation for a restoration. The frame and engine were in relatively decent condition.
So far I've built new wheels, rebuilt the swingarm, rebuilt the engine (had oem crank rebuilt, replated cylinder, new powervalve gears, new clutch and outer basket, oem bearings, etc..). Here's some eye candy:
Next week I should have the suspension finished, and will also hopefully have the frame back from the powdercoater. Then I'll be rebuilding the brakes and cleaning various parts. I also found a 97 oem pipe in really good condition which I'm going to try to remove a small dent from and repaint.
Originally I wanted to build a 97-style Splitfire bike. But after coming across a photo of a 92 KX with blue wheels my jaw dropped and I decided to go for the early 90s green and blue look. The frame is being done in flo green to match the flo green plastics I got. And I'm still unsure about the graphics.
I'm documenting as much of this build as I can in short time lapsed videos for those who are interested. Let me know what you guys think so far!
The Shop
I also made a last second decision Monday to anodize my fork tubes, and the shop I took them to turned them around quick. They also replated some hardware. I can't believe how nice they came out.
I'm waiting on vinyl fabric samples to decide on my seat cover. I got one from Pit Replica on ebay but it's a shade too dark so I'm going to make my own hopefully to match that early 90s light blue if I like one of the samples I get. And then I'm going to have the graphics re-done to match that blue. I might take that suggestion to use a clear background on the shrouds.
The fork lugs (esp the left one) were badly gouged. I spent some time with the dremel smoothing them out.
I also used some abrasive polishing wheels to shine up the shock body.
And also shined up the carb a bit and got some blue breather hose.
For the carb and petcock I used fine steel dremel brushes.
I was yet again disappointed with fabric samples I got which I was hoping to use for a seat cover. Everything looks one way on the computer and way different in person.
I also polished up the lower triple clamp and some various parts. I found a nos top triple clamp on ebay. You can see the difference in the finish between the two below.
The bike came with an aftermarket top triple clamp and bar mounts which I didn't like (ugly anodizing). I was going to get some new bar clamps but after grinding off the anodizing the one I've done so far looks awesome!
Original brake and shift levers, and rear master cylinder guard, all polished up.
The bike is nearly ready to come back together now. Just waiting on a few little parts, and some graphics from Decal Works.
The biggest holdup might be the seat cover. I've been trying to get one from Evo but I'm not hearing back from them. So I'll either use the one I already got or maybe have Decal Works make one.
Beauty restored. I have the exact bike and I’m working on this project as well. Slow but going for a slightly different look. Yours looks super clean!!! Congrats. Did you ride it at all?
Thanks man, yes I already put more than 66 hours on it. I ride it every weekend I can, but I'll be taking a break for summer.
Man maybe I’ll hit you up with some questions. If that’s cool. I’m about to send some stuff in to be vapor blasted. I’m super excited. Kind of afraid to strip all the gear off to the bare frame. Can you encourage me lol is it hard to put the forks ona md off. I want to powder coat the frame. I have rebuilt transmissions so I am mechanically inclined. I got these new radiator clamps. Stainless steel. They look waaaay better than the stock hose clamps. Did you ever try that phat head for the cylinder top? Thanks man
How much money did you have in the restoration. I have 2,200 in mine so far and I feel like I can drop at least 6k more. Expensive project. I’m just a nurse assistant so money is always tight with me
Here’s my bike. Going for a room and gloom look
Looks like your frame is already powder coated flo green (like mine). Nothing is hard on this bike, just time consuming. And expensive. It cost a few grand but I don't know the exact total. I stuck with the original head. It was in great shape. The motor overall was in good shape. Even the cylinder was still within spec, but I had it replated anyways.
I like that blue. I just ordered an aluminum engine bolt kit and it’s blue. A darker blue but I like it. So all the engine bolts and nuts will be a nice blue. I’ll continue that for most the bolts I think. I just ordered my hose clamps stainless steel. Way better looking than the slotted hose clamps
Post a reply to: 1995 KX250 Restoration