2007 KX250 retro build

Related:
Create New Tag

4/16/2018 7:51 AM
Edited Date/Time: 4/16/2018 7:56 AM

I've looked for a nice late model RM250 to build in '86 colors (complete with blue engine), but couldn't find a good candidate at a nice price.

Last weekend met someone selling a 2007 KX250 for a price I couldn't refuse. Bike was clean and thankfully, PO had not installed Renthal swingarm stickers (pet peeve!). Bike looked good, felt good, and ran well.

I grew up in the 80s, my favourite riders were Ward, Lechein and Matiasevich (and Bailey but that's for another build). I have a soft spot in my heart for the 88 KX's, so that's where this build is heading. Maybe. Hat tip to BobPA for his '03 KX125 old-school build, which helped inspire me today.

A few years ago I restored a 1989 KX125 and frequently ran into NLA parts, so I'm looking forward to working with a machine with better parts availability.

Photo

Here's the bike as I bought it. Still has OEM linkage and triple clamps. Suspension has "JO Suspension" decals but I'm not able to find a shop under that name.

Dissembly pics to follow.

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/16/2018 8:15 AM

Photo

Will probably shelve the R304 and opt for a quieter Turbinecore II silencer. Loud Pipes Close Trails!
Photo

PPO had a chain break which then broke the center case. The welds look good, but the PO used a little patch of JB weld to fill a spot the previous repair missed. I've ordered new center cases from Kawasaki.
Photo

Sticker on the back side of the front numberplate. Is this anyone here?
Photo

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/16/2018 8:21 AM

Two strokes are sexy af.
Photo

Photo

Photo

Photo

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/16/2018 8:24 AM

On order so far:

* OEM centercase set
* New UFO plastic kit
* Pro Circuit linkage

The plastic kit comes with white side number plates. Anyone know where I can get green side numberplates?

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/16/2018 1:19 PM

I want to say there was an 05 build last year that had green side plates. I think his name is rob fox or something like that. RV did a few laps at High Point on it before the start of the national. I'll try to find it for you

|

2017 RMZ450
2005 YZ250-sold :,(
1998 YZ250
2005 KX250F

80% of the time it works every time
IG @hamdaddyof2 & @2HRacing
Thanks to : Factory Effex, N2Dirt, Acerbis, DT1, Fasthouse, Matix, FMF, ASV, 100% & Mika Metals

4/16/2018 1:21 PM

|

2017 RMZ450
2005 YZ250-sold :,(
1998 YZ250
2005 KX250F

80% of the time it works every time
IG @hamdaddyof2 & @2HRacing
Thanks to : Factory Effex, N2Dirt, Acerbis, DT1, Fasthouse, Matix, FMF, ASV, 100% & Mika Metals

4/16/2018 1:37 PM

UFO makes the side and front plates in green. I have them on both my Kawasaki's.

|

Tomac and/or Anderson for 2020.....

4/17/2018 12:21 PM
Edited Date/Time: 4/17/2018 12:46 PM

Dis Gon B Gud

Photo

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/17/2018 12:45 PM

Inspiration:

Photo


Photo


Photo


Photo


Photo

Photo



Photo

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/18/2018 2:20 AM

Man those old kawis just remind me of the good old days. As i got older i rode more Hondas/ ktms than anything, but for for me the green bikes are where it all started. When a teenager i was poor, and all i ever found were blown up kx 125s. Crs were for people with money. I probably had every year kx from 84-95. I still have my first.
Will be a neat bike when your done. So you going for the 88-89 era look?

|

4/18/2018 5:42 AM

Byron909 wrote:

Man those old kawis just remind me of the good old days. As i got older i rode more Hondas/ ktms than anything, but for for me the green bikes are where it all started. When a teenager i was poor, and all i ever found were blown up kx 125s. Crs were for people with money. I probably had every year kx from 84-95. I still have my first.
Will be a neat bike when your done. So you going for the 88-89 era look?

I owned KX's from a 1985 KX125 up through a 2002 KX250. Even had a KX500 once that was way more power than I could have ever used. Restored a 1989 KX125 a few years ago too. Love the bright lime green. The 88s were probably my favorite look of the 80s. Loved the 92's with the blue anodized fork legs, too.

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/18/2018 8:35 AM
Edited Date/Time: 4/18/2018 8:37 AM

I miss my 88 KX250. I always wanted to put an 89 tank on it. That bike was probably the easiest 250 for me to ride (and I'm a small guy 5'6"). It was big but amazingly easy to throw around and handle. I switched between this and my 86 CR125.

|

4/18/2018 5:08 PM

How do these come off?
Photo

Stash is comin' in
Photo

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/18/2018 5:09 PM

Photo

Photo
|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/18/2018 5:12 PM

Bike was filled with transmission oil when I picked it up. Rode it five laps (about 7 minutes) and the oil is way below sight glass. The coolant looked a tad bit dirty, but I am beginning to wonder if the welded crankcase crack didn't extend further, allowing transmission oil to be drawn into the chamber and burned out the exhaust.

Photo

In any case, I have new cases. Need to order new crank seals just in case. Plan to use OEM Kawasaki for anything in the bottom end. Heard enough horror stories about aftermarket connecting rods and cranks.




|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/18/2018 5:54 PM

I know old older kawis the tank rubbers kinda snapped in. Its either that or it has spray adhesive hooding it, which i doubt.
If you are replacing cases, surely at least your doing all seals, crank bearings at least, right?
On making sure its all oem, you might find theres not alot of oprions for seals/ gaskets oit there anyway for that bike. But if you do need a rod, pro x make quality stuff. Nothing wrong there. The hot rods brand have been cheese since they sold to another in mid 2000s.
Where was your cases cracked? If trans oil was getting into piston area, it would have been smoking white, even if just a little. Those cases use semi drying gasket to seal to eachother, like all kawis, wonder if they split it to repair, and didnt seal it up good when going back together,
Drain the oil out of trans and measure it out. If you mesured it in, that will get you an idea of what was lost.
You painting frame green? Or leaving silver?
Its finny you mentioned an 85 125. That was my first 125 i ever had. Still have. I thought i was hot shit back in the day, grafted a disc brake rear from a 86 kx250 onto it. Maybe in a few years i'll be ready to bring it back to life, lots of good times on that thing.

|

4/19/2018 11:06 AM

Those gas tank rubbers are just glued on.

I ripped mine off and put them back on with super glue after my frame was powder coated.

|

4/19/2018 9:04 PM

Dropping this off at the powder coaters tomorrow:

Photo

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/20/2018 6:31 AM

I've got a spare flywheel weight if you are interested. Helps to broaden the power a bit.

|

Tomac and/or Anderson for 2020.....

4/22/2018 9:53 AM

What brands of spokes/nipples are worth looking into? Any I brands should avoid?

Pairing OEM rims up to these:
Photo

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/22/2018 12:30 PM

Bulldog spokes/ nipples are as good as anything. Great stuff.

Stay away from china stuff.

|

4/23/2018 5:57 AM

I can get you the tusk spokes cheap they'll lace up fine with oem.


I can discount most parts off Rocky Mountain

570-606-7687

|

4/23/2018 6:45 PM

What's the best option for a replacement clutch basket?

OEM Kawasaki: 13095-0048 - $282.79
Hinson: 151-1013 - $259.99
Wiseco: WPP3048 - $169.95
Barnett: 321-45-01014 - $233.10

Photo

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/23/2018 9:44 PM

Oem or Hinson. Only two I would trust

|

2017 RMZ450
2005 YZ250-sold :,(
1998 YZ250
2005 KX250F

80% of the time it works every time
IG @hamdaddyof2 & @2HRacing
Thanks to : Factory Effex, N2Dirt, Acerbis, DT1, Fasthouse, Matix, FMF, ASV, 100% & Mika Metals

4/24/2018 4:01 AM

queen of spodes wrote:

What's the best option for a replacement clutch basket?

OEM Kawasaki: 13095-0048 - $282.79
Hinson: 151-1013 - $259.99
Wiseco: WPP3048 - $169.95
Barnett: 321-45-01014 - $233.10

Photo

My 06 has the wiseco set up with no problems. But you're doing a build, money means nothing! Buy the Hinson, might as well get a new cover too.

|

4/24/2018 4:36 AM

RoostBuckets wrote:

My 06 has the wiseco set up with no problems. But you're doing a build, money means nothing! Buy the Hinson, might as well get a new cover too.

Did your Wiseco come with the clutch gear mounted to the hub or did you have to swap? If the latter were new cushions included?

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/24/2018 5:29 AM
Edited Date/Time: 4/24/2018 5:32 AM

No aftermarket basket will come with a gear, and any of the above is a better choice than the oem basket. Mitaka make a good one, as well as pro x.

And if not done, would be a good thing to drill the inner hub. Helps with oil flow thru the clutch. If you could buy a better inner hub, main difference other than coating would be that its drilled.

|

4/24/2018 8:25 PM

Wiseco baskets are nice, and guaranteed for life I believe. My bike has a Hinson, but I did not pay for it. Moose is also a good choice.

|

Tomac and/or Anderson for 2020.....

4/26/2018 10:52 AM

Good for me that everyone is buying black everything for their dirt bikes these days. Picked up a set of these on clearance for a few dollars more than I'd pay for the two wheel hubs (alone) separately.

Photo

Waiting on a couple special tools to arrive for continued engine disassembly. Stuff I know I'm replacing with OEM part numbers:

* Connecting rod & big end bearing
* Main bearings and seals
* Shift and kicker seals
* Clutch cover (for aesthetics)
* Ignition cover (for aesthetics)

Will either use a v-force, rad valve or just get a new rubber intake boot. One on the bike is starting to show signs of dry rot.

|

Ride like a girl!!!
2016 KTM 500 EXC-F
Current project: 2007 Kawasaki KX250-R7 retro build
Current project #2: 1987 Kawasaki KX250-E1 low-key restore
I NEED A PIPE FOR 1987 KX250 - thread

4/27/2018 7:11 AM

Haha First of all what have you got against Renthal stickers on swingarms? Easily one of the coolest designed brand logos ever.

I think that Hinson stuff is overrated, especially now there are so many more options. I'd go the wiseco straight up, I copy and pasted this directly off their website "We will stand behind all Clutch Baskets, Inner Hubs, and Pressure Plates by offering a LIFETIME WARRANTY if they were purchased after 1/1/2009. This warranty covers breakage and notching and covers the original purchaser when proof of purchase is presented directly to Wiseco Piston Inc.". Plus it's a 250 and sounds like your a trails/woods rider if you're taking off the R304 shorty, so your not really going to be giving the clutch a massive flogging to start with.

Mitaka and Pro-X are also good options, only thing with Mitaka is I've seen some of their baskets have sharp 90 degree edges on the inside of the fingers which can break the tabs off clutch discs and ruin a gearbox.

|

Vision Race Preparation.

Ceramic coatings, Suspension, Mechanical, Spoked wheels.

facebook & Instagram @vision_race_preparation

Personal Instagram @_yabba_dabba_dont_