1986 MX 250 KTM

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4/4/2018 10:03 AM

I recently picked up a 1986 MX 250 KTM and started rebuilding it for some Evo racing this summer. I have had to install new plastic, clutch, handle bars, suspension bearings and rebuild the brakes so far. I am currently waiting on graphics and a few other odds and ends. This is the same bike that my brother and dad rode in the 80's. I have been lucky enough to find some decals for the local shop that they rode out of. My goal is to make the bike look like one that they would have rode.The first picture is what it looked like when I bought it. If anyone has any parts laying around for these old KTM's let me know, parts are kinda hard to find.

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4/4/2018 6:29 PM

Looks like a pretty good starting point....

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4/5/2018 6:17 AM

Yeah it was a pretty good starting point. The hardest part for the old KTMs are finding parts. This one was at least all there. If it turns out as good as some of my other builds I'll be happy.

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4/5/2018 9:18 AM

Some really nice bikes you have there. Best of luck with the KTM. Looking forward to seeing it finished.
Greg

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4/5/2018 11:31 AM

Awesome....I like to see that a few more 80s KTMs builds starting to come up. It's pretty much a given with any old KTM that you will have to use Andre at:

http://www.enduroklassiker.at

What exactly do you need? Do you have a parts book for numbers?

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4/5/2018 1:28 PM

I have the same bike. Happy to share what info I've learned about these bikes, so feel free to ask. *Most* parts are the same as the 1985 model, but there are definitely exceptions. I've got a PDF file of the repair manual for the bike, and same with parts diagrams.. Let me know if you want me to hook you up with those.

First and foremost - have you inspected the condition of the clutch cover around the water pump seal? The clutch covers on these bikes are magnesium and they rot out really badly if you don't use waterless coolant, like what Evans sells. My bike ran when I got it, but when I went to change the oil, first it pissed a bunch of coolant, then it turned to a milky grey sludge that oozed its way out. I couldn't believe what I was seeing. That's when I learned about the clutch cover rot issue. It took me nearly 2 years to track down a NOS alloy replacement cover, which I scored off a guy in the UK, and it wasn't cheap. Here's my old cover next to the replacement cover for reference...

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I recently had Rich at DynoPort make me a pipe for the bike cool

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Positively, absolutely 110% obsessed with anything MOTO.

4/7/2018 10:51 AM

F150Motocrosser wrote:

I have the same bike. Happy to share what info I've learned about these bikes, so feel free to ask. *Most* parts are the same as the 1985 model, but there are definitely exceptions. I've got a PDF file of the repair manual for the bike, and same with parts diagrams.. Let me know if you want me to hook you up with those.

First and foremost - have you inspected the condition of the clutch cover around the water pump seal? The clutch covers on these bikes are magnesium and they rot out really badly if you don't use waterless coolant, like what Evans sells. My bike ran when I got it, but when I went to change the oil, first it pissed a bunch of coolant, then it turned to a milky grey sludge that oozed its way out. I couldn't believe what I was seeing. That's when I learned about the clutch cover rot issue. It took me nearly 2 years to track down a NOS alloy replacement cover, which I scored off a guy in the UK, and it wasn't cheap. Here's my old cover next to the replacement cover for reference...

Photo

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I recently had Rich at DynoPort make me a pipe for the bike cool

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Thanks for all the help! The clutch cover does have a small amount of corrosion. I’ve cleaned it up and coated it with epoxy paint. I’m pretty excited to get it going. That Dynoprt pipe looks awesome. Did it make a difference in the bike? I was planning on purchasing one

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4/7/2018 11:35 AM

jt.hagerty wrote:

Thanks for all the help! The clutch cover does have a small amount of corrosion. I’ve cleaned it up and coated it with epoxy paint. I’m pretty excited to get it going. That Dynoprt pipe looks awesome. Did it make a difference in the bike? I was planning on purchasing one

Cool, just stay on top of that clutch cover and see what your oil looks like when you change it... and like I said, make sure you're running a waterless coolant!! This is critical.

Honestly, I haven't even started the bike since getting the clutch cover OR the pipe. I've got over 20 bikes and severe ADD haha... So needless to say, lots of projects, most are 90% complete - just gotta focus and finish that last 10% haha. I have DynoPort pipe like this one on a 1992 Husqvarna 360 and love it.. Low end torque for days! I think I paid like $330 shipped on this pipe for my KTM - and FYI, Rich at DynoPort is a great dude but you gotta be patient. Think it was about 2-3 months for me to get this pipe.

I hate to say it, but I've been kicking around the idea of possibly letting this bike go. I love KTM and euro bikes, so I'd really love to get this '86 finished up, since you don't see many of them out there.... but two things I don't have much of are time and space. IF I do end up selling, might you be interested in the clutch cover and pipe?? Again, major IF haha... I also scored a NOS set of Acerbis side panels out of Italy for the bike (not installed)... I see you put new plastics on yours... are those the reproductions from DC? How did they fit??

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Positively, absolutely 110% obsessed with anything MOTO.

4/7/2018 4:36 PM

F150Motocrosser wrote:

I have the same bike. Happy to share what info I've learned about these bikes, so feel free to ask. *Most* parts are the same as the 1985 model, but there are definitely exceptions. I've got a PDF file of the repair manual for the bike, and same with parts diagrams.. Let me know if you want me to hook you up with those.

First and foremost - have you inspected the condition of the clutch cover around the water pump seal? The clutch covers on these bikes are magnesium and they rot out really badly if you don't use waterless coolant, like what Evans sells. My bike ran when I got it, but when I went to change the oil, first it pissed a bunch of coolant, then it turned to a milky grey sludge that oozed its way out. I couldn't believe what I was seeing. That's when I learned about the clutch cover rot issue. It took me nearly 2 years to track down a NOS alloy replacement cover, which I scored off a guy in the UK, and it wasn't cheap. Here's my old cover next to the replacement cover for reference...

Photo

Photo


I recently had Rich at DynoPort make me a pipe for the bike cool

Photo

Photo

jt.hagerty wrote:

Thanks for all the help! The clutch cover does have a small amount of corrosion. I’ve cleaned it up and coated it with epoxy paint. I’m pretty excited to get it going. That Dynoprt pipe looks awesome. Did it make a difference in the bike? I was planning on purchasing one

F150Motocrosser wrote:

Cool, just stay on top of that clutch cover and see what your oil looks like when you change it... and like I said, make sure you're running a waterless coolant!! This is critical.

Honestly, I haven't even started the bike since getting the clutch cover OR the pipe. I've got over 20 bikes and severe ADD haha... So needless to say, lots of projects, most are 90% complete - just gotta focus and finish that last 10% haha. I have DynoPort pipe like this one on a 1992 Husqvarna 360 and love it.. Low end torque for days! I think I paid like $330 shipped on this pipe for my KTM - and FYI, Rich at DynoPort is a great dude but you gotta be patient. Think it was about 2-3 months for me to get this pipe.

I hate to say it, but I've been kicking around the idea of possibly letting this bike go. I love KTM and euro bikes, so I'd really love to get this '86 finished up, since you don't see many of them out there.... but two things I don't have much of are time and space. IF I do end up selling, might you be interested in the clutch cover and pipe?? Again, major IF haha... I also scored a NOS set of Acerbis side panels out of Italy for the bike (not installed)... I see you put new plastics on yours... are those the reproductions from DC? How did they fit??

Yeah I might be interested in the pipe and cover. The plastic is DC stuff,it fits ok. The original side panels I have are in pretty good shape, the only reason I bought new ones is the DC side panels were the only panels that I could find pre-pro ted backgrounds for. I’m having EVO MXmake new decals for it.

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4/12/2018 5:06 PM

Made some progress today. It’s looking better. Photo

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1/13/2019 1:01 PM

Hay,
Very nice bike..
I have a lot of part for ktm mx 250 84,85,
My email
Kampus.b@gmail.com

Regards, B

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1/13/2019 1:42 PM

Hope you get all you need for parts. I had to give up on my 83125.

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1/13/2019 3:49 PM

F150Motocrosser wrote:

I have the same bike. Happy to share what info I've learned about these bikes, so feel free to ask. *Most* parts are the same as the 1985 model, but there are definitely exceptions. I've got a PDF file of the repair manual for the bike, and same with parts diagrams.. Let me know if you want me to hook you up with those.

First and foremost - have you inspected the condition of the clutch cover around the water pump seal? The clutch covers on these bikes are magnesium and they rot out really badly if you don't use waterless coolant, like what Evans sells. My bike ran when I got it, but when I went to change the oil, first it pissed a bunch of coolant, then it turned to a milky grey sludge that oozed its way out. I couldn't believe what I was seeing. That's when I learned about the clutch cover rot issue. It took me nearly 2 years to track down a NOS alloy replacement cover, which I scored off a guy in the UK, and it wasn't cheap. Here's my old cover next to the replacement cover for reference...

Photo

Photo


I recently had Rich at DynoPort make me a pipe for the bike cool

Photo

Photo

You do not need waterless coolant to prevent corrosion in magnesium, and there is zero proof that evans coolant prevents corrosion in magnesium, plus evans coolant does not cool nearly as well as a standard 50/50 coolant mix. In fact, there are coolants specifically designed to prevent corrosion in magnesium.



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1/14/2019 5:24 AM

Mx746 wrote:

Hope you get all you need for parts. I had to give up on my 83125.

I actually just sold a 83 125 KTM to a buddy. He has found everything he needed so far.

https://www.enduroklassiker.at/en/

This place has a lot of parts for older KTM's

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1/14/2019 12:40 PM

Man Rich can do some beefy pipes. Was always impressed with his work.

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3/6/2019 4:53 PM

I am working on a 1985 KTM 250mx resto-mod and would be interested in that pipe F150Motocrosser if you are still considering selling it.. I sent you a PM. Really cool thread jt.hagerty!

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