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

**Arronduke** · 28th May 2011, 21:58

Last up... these nuts and bolts to go..

All exposed nuts and bolts $50 plated.
Just for fun..

Dam need to clean that bench..

botton speakers.. yep killed them.. 200w .. but I got new ones .. and yes one set each back corner....!

**cheese** · 28th May 2011, 22:15

Just get some new drivers for your speakers from jaycar. Be cheap as.

**barty5** · 29th May 2011, 20:28

Originally Posted by Arronduke

Well things have slowed down in the build front.. run out of money and have spent next months bike alliance already this week. I'm thinking build the bottom end and put it in the frame so I can add suspension and have a rolling chassis. Motor is part of the chassis.. uses same bolt as swing ..(for the newbees).

this will take a while so I have a complete gasket and seal set is coming.. already had a top end gasket and seal set.. LOL

I get bearings cheap through work... all the wheel brings were $15. no idea what they should have cost.. no dought it will be $14 ...LOl

Cleaning... very sick of cleaning.. mental note... get wife to clean bike parts..... after all cleaning is what women do best after getting me a beer..

So back to the bike... still the story of the cases... yep they are separated..

yes damage.. can say I did it but it looks like it. Might have been the impact driver on the gear selector hub. I complained for a while. Other wise the crank cases open super easy. One crank bearing slid off... I can slid it on and off.. is this normal?
Other side is stuck fast and I will press it out at work this week.

So long story short bearing retainers for the gearbox broke off. What now.. there is a small lip left but useless so it will be locktite bearing retainer and put the retainers back to check the bearing is in the right spot....

honda use little horse hove shape bits of steel with a little hole in them counter sunk to hold in bearing yuod just have to drill an tap the casing for them to work

**cheese** · 29th May 2011, 20:35

Hmm can you sleeve the housing or use a larger bearing?

**barty5** · 29th May 2011, 20:45

try having a look at part number 11http://fiche.worldofpowersports.com/...=13&A=290&B=14

**Blagger** · 30th May 2011, 21:45

Have you thought about building some shelves for the garage?

**Arronduke** · 31st May 2011, 19:27

Originally Posted by barty5

try having a look at part number 11http://fiche.worldofpowersports.com/...=13&A=290&B=14

Dam good idea... might see if I can fit somthing like this... got to say loctite bearing retainers is dam strong. I used it on my RG where a bearing spun and I am pleased to say this one looks like it might have spun a little but the brearing is still a tight fit.. will have a look at both options but i am leaning towards loctite. But i will look at adding a retainer.. piece of mind you might say.

**Arronduke** · 31st May 2011, 19:31

Originally Posted by cheese

Just get some new drivers for your speakers from jaycar. Be cheap as.

Did look at that but got a second set for $100 bucks... there are 3 drivers in each speaker and from memory the jaycar ones were $40-$50 each... the rubber seal died on mine and tweeters blown. Jaycar used to sell kits to replace the outside rubber on speaker but don't any more and agai the cost would have been more than $100.

so all in all it ok.. like the speakers nice and high as the sound trevels better.. a good point for living in the country... no noise control...

**Arronduke** · 31st May 2011, 19:51

Originally Posted by Blagger

Have you thought about building some shelves for the garage?

yea I am building a garden shed to make room... ride on mower and crap out.. also I have 9 bikes in my garage and 2 are not mine.. they have to go.

Then I think its time for a clean up with some shelfs and cabnets etc... wife thinks she should help tidy it up...

cant have that..!!!!! there might end up being a sawing machine in there...

**cheese** · 31st May 2011, 20:10

Originally Posted by Arronduke

Did look at that but got a second set for $100 bucks... there are 3 drivers in each speaker and from memory the jaycar ones were $40-$50 each... the rubber seal died on mine and tweeters blown. Jaycar used to sell kits to replace the outside rubber on speaker but don't any more and agai the cost would have been more than $100.

so all in all it ok.. like the speakers nice and high as the sound trevels better.. a good point for living in the country... no noise control...

Surplustronics are cheap too.

**Arronduke** · 31st May 2011, 21:25

Got some part thanks to Barty...

The best bit was... airbox mubflap... new was moon beams and I did not want to buy a new one... for an old bike..
So cheers.

also seperated the crankcases and removed the crank.
One bearing slides on and off... that cant be good... the other bearing was that rooted it sounds like a train when you turn it... also one of the crank seals was fucked... which was why it was so hard to start and would not idle... thats my guess any way.

this is the train job...

crank bearing seems Ok.. no up and down movment.. have not measured the sidways movment. But i thinki will get it rebuilt anyway, or repalce...

These suckers are hard to remove... got the larger bearing out using a 6mm rod bent on the end so it fitted in to the bearing hole and attached some vice grips to the top... heated the crankcase with heat gun and tapped the vice grips with a hammer move the rod around to aviod locking it up and out it came... still more blind hole bearings to go.

Am going to make a slide hammer as its so easy to remove bearings.. once the bearings are out ... off to the bearing shop...

**noobi** · 31st May 2011, 22:26

Just out of curiosity how much was a genuine mud/shock guard?

**Arronduke** · 1st June 2011, 22:44

Originally Posted by noobi

Just out of curiosity how much was a genuine mud/shock guard?

No problem.. from memory it was $45 ..or very close..

**Arronduke** · 2nd June 2011, 20:25

Brought the slide hammer and bearing removal tools home from work. Now with the right tools bearing removal is a lot easier.

Still sucks removing bearings that don't want to be removed.

Only one that I can't remove and it seems fine... that is the one at the bottom of the clutch engagement arm. The bottom bearing is way down inside.. and it will stay there. Got the top one out as it was missing some needle rollers. So in total thats 10 bearings.

Off to the bearing shop tomorrow...

**Arronduke** · 3rd June 2011, 22:21

Had to remove a broken screw from the magneto side crank case... only way to remove it is drill it out.

Start with a dot punch and hit the dot punch on angles until it in in the middle.
Then drill a small hole right though.

Next use a bigger drill and often it will bite and start to wind in with the drill bit... not today.. this sucker is well stuck.

So larger drill.. and finally a 5mm drill for a 6mm thread... and hope you are close to the middle and not fuck the thread.

90% of the time the 2nd drill will grab the broken screw and wind in.. then reverse the drill and remove the screw but as i said not this time. Or better still use an eazy out in the second hole but I don't have any.

With luck on my side and the help of a 6mm tape its all good to go.

Cleaned the crank cases some more what a bitch of a job.. and never made it to the bearing shop as I was too busy.. after all its a long weekend and I had to go home at 2:30pm...