1990 KX250 build

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1/6/2015 5:07 PM

I picked up this 1990 KX250 off Craigslist for $700 when I was visiting California with the family over the holidays. It is currently awaiting shipping to NZ, should arrive the first couple of weeks in Feb.
I was inspired by the "Project 90" build Mathes did recently and I'd like to achieve something similar.
This is not going to be a factory replica or tribute bike and I'm not concerned about everything having to be period correct, it will be used for VMX and club days so it needs to be a fully functional race bike.

The motor runs and sounds quite good but it will get a full rebuild as part of the project and I'll be replacing the carb with a new PWK airstriker.

The forks are in good shape and don't leak but will obviously get a full service and set up for my weight (as will the shock)

It has a Pro Circuit works pipe that looks like it's been on there since 1990, it's pretty banged up but with no new ones available I think I will be forced to try to recondition it.

The shock and forks have pro circuit decals on them, I have no idea whether they were ever worked on at pro circuit or if the decals were just stuck on there by someone in the past.....who knows really. It also has a strange looking one piece bar clamp setup that I haven't seen before, perhaps some one on here may be able to identify what it is.

I'm hoping Kidkawie can be of help with information and knowledge, I've never owned a Kawasaki before so I'm not familiar with these bikes. I understand from reading some of these build threads that the older KX stuff is hard to get now, so any help sourcing parts would be appreciated. In particular I will need a replacement fuel tank and fork guards.

Here are a few pics

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1/7/2015 11:21 AM

Cool bike man! Your 2 main issues are powervalves and fork springs. It has 41mm KYB's and no options for springs unless custom. If you plan on really racing it I'd swap those out for a set of 43mm from a 91-95 KX. Replacement powervalves are getting hard to find. Hopefully they are good.

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04 KX125
94 KX250SM
75 Z1-900

1/7/2015 2:15 PM

Thanks for the advice on the forks, I'll look for a good set on ebay. Do you know if the wheel, brake rotor and calliper will fit the newer forks? also, will they fit the 90 triple clamps as well?

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1/7/2015 2:53 PM

Nice buy, looking forward to seeing how it progresses

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1/7/2015 3:47 PM

I'm also keen to know what options exist for modern foot pegs to fit this model bike

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1/8/2015 7:26 AM

You need the triple clamps for sure. 125's do not have removable bar clamps like the 250's. I can't comment on the wheel/brake. If you can't find a complete front end I would see if your '90 parts fit the newer forks. Also, 91-93 bikes had the blue fork tubes, the 94-95 would "look" more original to your bike. For the pegs you can find some aftermarket pegs for KDX's. The '90 footpeg part number doesn't cross over to the old KX/KDX pegs but I think they will fit.

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04 KX125
94 KX250SM
75 Z1-900

1/8/2015 7:26 AM

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04 KX125
94 KX250SM
75 Z1-900

1/8/2015 4:03 PM

BM255 wrote:

I'm also keen to know what options exist for modern foot pegs to fit this model bike

I've got a pair of the IMS pro series pegs on my '91 125, no complaints with them.

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1/8/2015 4:17 PM

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1/9/2015 1:08 AM

Kidkawie wrote:

You need the triple clamps for sure. 125's do not have removable bar clamps like the 250's. I can't comment on the wheel/brake. If you can't find a complete front end I would see if your '90 parts fit the newer forks. Also, 91-93 bikes had the blue fork tubes, the 94-95 would "look" more original to your bike. For the pegs you can find some aftermarket pegs for KDX's. The '90 footpeg part number doesn't cross over to the old KX/KDX pegs but I think they will fit.

Thanks for this, I found a guy in NZ selling a 91 roller so was thinking of taking the whole front end off it, however the VMX rules here wont allow any parts from bikes later than 1990, so the blue 91 forks will make it really obvious. May just have to work with the stock forks until I can find some from a 94/95.

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1/9/2015 1:10 AM

They look really good, will definitely get some.
Am I correct in assuming they simply fit straight on with no modifications?
Cheers

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1/9/2015 2:23 AM

Good man we need more pre 91 bikes in the series over here -next race is in morrinsville next weekend

I have sent you a pm let's try and hook up soon
Cheers
Craig

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1/9/2015 2:38 AM

Sounds good Craig, I decided not to get the Bradshaw bike out into the dirt, it's a bit of a garage queen now. Besides it doesn't qualify for the pre 91 class anyway.
So this will be my VMX bike.
Speak soon

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1/9/2015 3:34 AM

I had that bike in the past!
It was a blast on fast tracks,very good on jump but a bit stiff to turn tight.
BTW cool bike and seems like you are doing really a great job so far!
wink

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My job @ www.spah24.com

1/9/2015 3:28 PM

BM255 wrote:

They look really good, will definitely get some.
Am I correct in assuming they simply fit straight on with no modifications?
Cheers

No mods required at all, they mount right up to the stock mounts.

My mounts were pretty worn , so I ended up building up the mounts with weld until before dressing back with a file so I didn't have sagging pegs.

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1/10/2015 6:06 AM

Cool bike. Are you going to try and find original graphics for it?

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1/10/2015 1:16 PM

Ewan wrote: [LINK TO IMAGE]

BM255 wrote:

They look really good, will definitely get some.
Am I correct in assuming they simply fit straight on with no modifications?
Cheers

Ewan wrote:

No mods required at all, they mount right up to the stock mounts.

My mounts were pretty worn , so I ended up building up the mounts with weld until before dressing back with a file so I didn't have sagging pegs.

Thanks man, I've ordered a set!

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1/10/2015 1:21 PM

nascarnate326 wrote:

Cool bike. Are you going to try and find original graphics for it?

I think ill just get a set of replica graphics made. EVO MX do a good job, they use really thick vinyl that is durable and looks good for a whole season of racing

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11/16/2015 1:15 PM

Have you done any more work lately? Keen for some updates smile

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8/4/2017 11:36 PM

Hi all, I haven't posted updates for ages, been working on this project on and off over the last year or so.
Today it finally got to see the light of day and I'm pleased to say it's all but finished, just a couple of small finishing touches to do.
This thing was hands down the biggest pile of sh*t I've ever worked on, everything, and I mean everything was either broken, missing, or worn out. I had so many set backs that I almost gave up on it a couple of times.
I have replaced virtually everything!
I got it running and put it through it's first heat cycle riding up and down the road, it ran well.
I'm looking forward to getting it run in, set up and ready for the VMX series starting in September.














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8/5/2017 5:32 AM

Very nice job! I remember those coming out and how wild that design was. I still think that color with those graphics are one of the coolest looking OEM designs ever.

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8/5/2017 10:25 PM
Edited Date/Time: 8/5/2017 10:28 PM

Good job. What brake disks are those? I need some new ones for my CR and those look Honda OEM-ish.

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8/5/2017 11:43 PM

Rockinar wrote:

Good job. What brake disks are those? I need some new ones for my CR and those look Honda OEM-ish.

Thanks man, the rear disc is the original, I just cleaned it up, the front is a brand new replica of the OEM, check out metalgear, it's a company in Australia, they make replica discs for pretty much everything

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12/28/2019 2:44 PM

Hey I know this thread has been laying dormant for a while but I’m hoping I will get response. I have ‘90 kx250 sat in my garage which Is in need of some reviving. The biggest issue I’m having is finding an exhaust for it. Am looking for a ProCircuit Works pipe just the one on BM255 bike.

Now at the risk of making my self sound real stupid, will an ‘89 exhaust fit a ‘90?? I’m finding people selling the pipe for the 1989 bike but not the 1990.

Any ideas?? It’s much appreciated 👍

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12/28/2019 3:16 PM

'89 pipe won't fit. '90 and '91 use the same pipe with '92-'93 being a different pipe and '94-'98 as well.

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12/28/2019 3:34 PM

Thank you for clearing that up dude i appreciate it 👍. That means the search continues lol

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12/28/2019 7:14 PM

The 90 stock pipe was actually a very good performing pipe, if you still have the stock pipe you can do this with it... I have read that O”Mara & Ward would often run the stock pipe In 90.

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12/29/2019 11:52 AM

Hello guys thank you for getting involved. The hand made pipe for the 88/89 bike looks awesome and I will get in touch to see if he can help also the stock pipe looks awesome like that. I do the stock pipe but it’s pretty beat up.

This is a slight change in subject but if anyone gets wind of some engine casings for a 90 or 91 that are for sale or going spare please do let me know!!

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1/27/2020 9:20 AM

Looks amazing!! What paint did you use for the ignition cover?

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1/27/2020 6:29 PM

Bike looks great!!!

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