KX250 rebuild - after all I've ridden it half a dozen times and it's worn out

[flyingcr250]

Oh man you gotta do something with those grotty foot pegs....

[DVS ME]

Nice work glad to see it hasnt been forgotten! Not long now few more nights/beers and you will be scaring your self with the new found power.
Hope you intend to get it dirty after all this.

[thecharmed01]

Oh man you gotta do something with those grotty foot pegs....

haha I thought the same thing! It's looking awesome though!

[TrentNz]

haha I thought the same thing! It's looking awesome though!

sand blast and a flick of paint mabey?
or new ones

[Arronduke]

Oh man you gotta do something with those grotty foot pegs.... WTF

Now what is wrong with my foot pegs? They have been plated, they are nice and clean and fuck me they look fine!

Pink paint now thats an option..... .... or keep them. Haaa I have no idea... way I look at it they are clean... will not rust and will only have my dirty boots on them. Bit like the wifes ass when she plays hard to get...(give them 9 inches and they take your house)... glad thats not my problem..heee.. best not to give them more than they need.



Now down to work... Corona was what was in the fridge... so I had to open 4-5 of these while I think about :

1) Cast bearing retainer in the crankcase are broken (not me officer) and the bearing will fall out and destroy my new engine.
2) I need to install the crank with NO special tools and assemble the crank cases without rooting the crank and cases.
3) If I fuck up the above I will sulk and need to look for a suitable tree to support my weight, close the garage door and run all 9 bikes and drink meths or admit I am nothing but a looser and take the crank cases to a shop.... OH the shame of it... option 1 and 2 must be better than the shame of stand in front of a pimple faced apprentice asking me what have you done....? why did you do that? with a silly smile. (I'll be thinking dam if that was me I would squeeze that... smart prick)

So all the corona is gone and it time to get serious.... open a red.!

With a new 6 beer bullet proof armmer its time to start.... thinking is over, time for action. After all thinking never works!

First off... those dam cast bearing retainers... I ground back what is left of the cast retainer and with luck there is a threaded hole sitting there all ready for the job, grind a bearing retainer and check gearbox clearnace and I'm good to go. Dam I am pleased. You will have to agree it looks good.



Next I put the crank in the freezer for 2hrs... place the primary side crank case in the oven and heat to 150c bearins and seals... no problem. then place the crank case on some wood... pray and get the crank out of the freezer. Dam it was cold and it fell stright in.. perfect. Hell better open a beer and celeibrate.

Then I installed all the gearbox and selector forks forks and shit. Made sure they worked as they should... other words made sure I could select all the gears. There were marks on the selector drum so I made sure I was able to select all of them. Perfect. (things are going too well and at any moment I will find a F$ck up).

Crank in place... and dam it was easy.

[Arronduke]

So the crank is in the primmary side and I'm half way there.

OH went to the kids hoda camp and had to take the wife....... (ok I have lost my licence) and she loved it... so a new bike has been added to the garage.
DR200 eletric start which i think is perfect to start riding on.. after all she has never riden a bike. Yes yes i know a CRF150 would have been perfect but hay that cost too much and remember this is for the wife. Got to say its cool.



I know I know... WTF no beer fridge! sham.. it died.

Anyway... time to assemble the crank cases.

Crank case with the crank in to the frezzer..

[TrentNz]

finally an update you bastard!

[Arronduke]

bugger was not ment to post just yet.

the other half went in to the BBQ... (when i put the crank case in to the oven to insatll the crank it stunk out the house and ... yep un happy wife as usual!) fuck it stunk.. heee... time to put my boots on.

So this time I used the BBQ.



Took the crank case with crank out of the freezer... yep it was cold.


applied gasket shit... yammaha bond stuff and assemble.
It all went togeather perfect... 3mm gap which needed a tap with a soft hammer and bingo ... ok a bit more than a tap to close the 3mm gap but it went togeather and bolted up. And the crank turned as did the gearbox....

Pleased as you would expect....
thats all folks for now..!

[Arronduke]

OK I lied....





Also spent 350 notes this week on all the little bits like exhasut mounts and gaskets etc... dam forgot new foot pegs

[Adriaan]

legend.

I love this thread.

[TrentNz]

whats left to do now?
it looks better then my bike and mines an 07

[Ender EnZed]

legend.

I love this thread.

+1

I've only read the last page but I thoroughly approve of the alcohol and the number of bikes in the shed.

[george formby]

finally an update you bastard!

Yeah.....

I do believe Arronduke's prose is riper & more pungent as the thread & build progresses. As inspired as I was I now know my freezer is not big enough to do my own maintenance. Booker prize short list surely?

[Arronduke]

Been a busy week... buying bits.
If anyone ever says... man rebuild it.... DON'T.

Old MX bikes are old for a good reason... they are fucked.! period.
Everything is rooted, munted, fiddled with and basically molested. Hell it sounds like I got my bike from sif's

Not wanting to whine tooooo much.. but a few new things were needed this week.

Clutch basket... has been raped and never got to cook eggs...its got more lumps than a 15yr old after Easter or your knob after a weekend in a whorehouse. The only differance is the cost versus pain to fix... hee .. The later will be both if your busted!



So a new one was on the list... now like everything in this world its not as easy as one expects... I expected to pick it up and install this sucker... OH no... you have to build the bitch and in the fine writing on the instructions it say... no warrantee... WTF. So don't munt it I tell myself.

Step one drill out the rivits with drill supplied... make sure you use a dot punch and get the middle... and dont drill for china. Bad idea. You are only wanting to break the riviot head.



plate removed.



make sure the gear goes back the right way...and bash out the gear with a socket of the right size...



Use locktite and asseble... job done.




And did I mention... you need a press to put the main gear back in the middle... what a PITA... but now it looks cool

So whats next on the rooted list... kick starter... yep its slipped when I rode it... So after much time on the net and a few ales I found that a few people ground the gears with a die grinder to sharpen the teeth... me think I can do that.

So I took the gears to work and used a surface grinder to take 0.5mm off each tooth, everthing is nice and square. I will use a 1mm spacer between the ratchet and the spring to take up the gap and add a new spring. result is very cool... nice sharp teeth. Pleased my misses doesnt have teeth this sharp

End result... un tested looks mint.





Teeth that sharp will remove a forskin in seconds, I'm hoping that will be the end of kick starter slipping issuies.

OK so what could be munted and raped next... easy.


power valves... so what is the point in replacing them, after all its just the end thats fallen off. BUT on closer inspection the missing bit lifts and lowers the exhaust port. So guess what... yep after all the work who wants a motor that does not run as it should. New power valaves purchased.



Open... like a good box.


Closed .. say no more.


BUT they now work.

What else has I done? Looks like FA but the piston is in... new piston installed and head on... getting close. BUT there has to be something I have done wrong, after all the beer of the days was NOT Lion Red.



You might ask.. why is the clutch not installed? Good piont the lick start spring I ordered was a little short... it turned out to be the spring for the kick starter. Now who ordered the wrong part? I say no more.

[TrentNz]

looking good.
make a video