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

[flyingcr250]

i love christmas

[josh_oj]

ha this thread is awesome. love watching the rebuild

[krad_nz]

I found the exact same thing on my 2006 KDX200 when I did the top end. One of them was damanged, just like your two. I just replaced it, I'm guessing its a fairly common issue. I didn't have to replace it, but it felt bad just putting it back in like that.

[Arronduke]

I found the exact same thing on my 2006 KDX200 when I did the top end. One of them was damanged, just like your two. I just replaced it, I'm guessing its a fairly common issue. I didn't have to replace it, but it felt bad just putting it back in like that.

Thanks for your post..... now I have to replace them...cheers !!

[barty5]

Thanks for your post..... now I have to replace them...cheers !!

checked and pull the PVs out of the motor must be a kawasaki thing to use the same part number but the parts to be completely different as for the other bit they are there hows 40 sound anything else your after ?

[Arronduke]

Being a frinday and all... time for a beer...mmm what are my options...?

Go inside the house where the wife is waiting for be to paint the kitchen roof which I promest to do and its half done so there is shit everywhere... or open beer and go to the shed...hmmmm ... love to just ge the fly wheel off.

Give me 30min ... grab 2 beers and off I run... some Neil Yonng on the 165rms garage stereo and I'm in to the flywheel removal.

First attempt BAD... then get my no fuck tools...!



First the red handled strap... no this is very cool... holds clutches.. flywheels etc.. this is the second one ive had and each has taken a betting... seriosly good.. and cheep.... rating 10

flywheel puller... well its a flywheel puller.. $20 + $5 freight from Barries Point Rd.. tyres place... Cycle treads... to lazy to pick it up..$5 ok. I've rooted one of these before on an other motor because i did not scew it in enough and the pullers thread stripped...shit. Why crao in the thread I thought I had... never again and the thead on this puppy was bad... CRC.. yep love the shit and a tooth brush... screw it in... and.. rating... 7 ( it did not strip) often make my own but $20 bucks..hay.

Impact gun... a must. Saves so many bolts and shit from being stripped.. ... hmm I like strippers.. Oh back to impact driver yes very cool. Paid good money for a mid range job 20 years ago and it finaly dies.. plastic trigger dies... other wsie mint.. 1/2 inch job. Went for about 6months with no rattle gun.. even borrowed onr for a job... dam its a must have.. bunnings $130 odd for 1/2 inch... found a chinese 3/4inch mother for $99.rating 10 for must have and 500 man points... after all who owns one of these?

Heat Gun... Gas is better or butain tourch... but i dont have one of those... .. so heat gun.. very good. Best way to assemble a motor heat and cool..!

So the story..

Heat flywheel with heat gun, fly wheel puller, and 3/4 inch rattle gun and after 30min and soaking in CRC it came un done... all good.

next whats under the fly wheel must come out..
Could not undo one screw... chissel on all and only one did not come un done...had to drill the head of the screw off.






Next clutch... all started good... except the clay some bugger put in the engine to slow me done..
Then the clutch nut... WTF... I gave it every thing I had with out rooting it... Im talking 3/4inch impact gun... going hard. naaaa nothing.. WTF

And again WTF.. is this looks like its crimmped on


How am I going to get this off... dremal.. grinder i am thinking... Can you belive this thing even went..? shows what a betting a MX motor can take and still run.

OH.. if you got this far.. yes fly wheel off... paint roof and back to shed with an arm full of beers.. must get a beer fridge.

Looking forward to Sunday .. Bucket racing.. second ride on my bucket.. and yes fell off it first time.. not my fault I say..! but it was not painted then.. graphic and seat to go.. FXR150. ( I know its not a MX machine but its cool) needs numbers for the weekend.


last bucket was a CG125.. bored it out to a 150cc.. using CB550 piston and CB750 barrel.. push rod engine.. longer duration sigle cam.. 3speed commuter gear box swapped for a 4soeed XL100 box... dropped stright in.. heee. Spent heaps.. but without suspention and brakes it was a fun ride.. sold for $500.. cost $2000. great deal.


"dont forget the milk on your way home"

[Arronduke]

checked and pull the PVs out of the motor must be a kawasaki thing to use the same part number but the parts to be completely different as for the other bit they are there hows 40 sound anything else your after ?

Hell what a dude... may you have many sons...

$40 notes sounds like a deal from hell... yes.. airbox mud flapp... its rubber.. $50 notes for a new one and mines split.. splut yep... cant put that back. dam... new one needed. Just about to order new... along with airbox seal thing ... $80 moolars.. must have.. dam expensive... ..

insure a 2005 model.. (dont want to be greedy) set fire to 1992 model... hot enough to melt ali....

and there will be more... most appriciated.. cheers.. Long Live kiwi Sprit..

[cambocambo]

This is a cool thread, enjoying seeing the progress.

[Arronduke]

This is a cool thread, enjoying seeing the progress.

Thanks ..

[Arronduke]

its official.... I hate this motor and it hates me...Now with that sorted I descided to start hitting it with a hammer and it felt good.

Yep you might have guessed... that dam clutch nut would not come off.... I tried everything... bastards might as well have weld it on.

I tried all my trickes... heat, impact gun but no go... so I ground it with a dremal, I drilled it with a drill... I smacked it with a chisel... yep it was pissing me off. using these black smith methods had me worried I would root the thread of the shaft and I was farily sure there would have to be a mark... and this is how the nut looked after some cosmetic surgery.'



best bit was not a mark on the shaft or thread... luck I say..!

Even with this it ran... looks OK in side and little waer on the clutch hub.

[Arronduke]

checked and pull the PVs out of the motor must be a kawasaki thing to use the same part number but the parts to be completely different as for the other bit they are there hows 40 sound anything else your after ?

Sorry to muck you around but I dismantled everything some more this afternoon.
Any chance you might have a few of the following?

Impala shaft rooted and impala
Power valve rubber cover rooted
Rear axle bolt and nut.. works but the thread is almost gone...
Clutch hub nut.. not usable
Rear brake reservur

Thanks for the help with the other bits.. I'll PM you my address and you send me your account details .. I will add $5 for postage if you think that will cover it.

cheers

[Arronduke]

Not much to report....

Been cleaning stuff... and all the bolts are getting plated so they should be nice and new looking...
Had to drill out a broken bolt from the front rim which dies removing the disc... all done and no damge...



Man that airbox was dirty... full of sticky crap.... rubber airbox flap is split so tried gluing it, its not on the air box at the mo..... hope to get a secondhand one.

[grantman]

Arron
You look like you are good at cleaning

When are you coming over to Clean mine ?
its got 20 years of dirt holding it together !

[Arronduke]

Grant... if I cleaned your bike it would never go again... do you clean any of your bikes?

let me think...

Dirt bike... nope.. as you have stated.
F5 track bike... (bucket) nope.. and its held togeather with tape and cable ties and not to mention you fell of it on Sunday... could not handle a little rain on those slicks...

And you have a Road bike... let me guess NO WOF or REGO... tell me if I'm wrong... hmmm I can't hear anything... what else...

Oh almost forgot... those pocket racer things which make you look like your riding a petrol powered vibrater... What are the call... pocket bike... Gay...

Now with all in insults out of the way... remind me did I also pass you on Sunday?
HEEEEEE

Oh hell that picture of me on my old race bike... no is that not you BEHIND ME?

[Arronduke]

Enigne is comming apart... slowly.

WTF



Yep one water pump shaft.... = water in crankcase.

My guess is these crank cases have never been apart... 19years. Why do i say this... the big book of everything... The NET ... many posts tlak about getting the clutch hub off.... super tight... the longer they are on the worse it is to get off... (ha... the price for getting old... the harder it is to get off..) LOL..

Next the inside of the crank cases is un- touched.. no dents.. rounded bolts screw driver marks etc.. white paint on parts showing that it not been apart. So I like that..!



As we speak my steering head outer shells are in the freezer as is the steering head getting ready for putting the steering head bearings in to place tomorrow...add heat gun to incease tollerance ... add BIG hammer for when it goes bad and tube to hit the lower bearing in to place.

All good..