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

[Arronduke]

Seems that no one wants to post... I might as well talk to myslef...

Diary... 4pm... wife not home for 1hr and kids have food and watching TV... tell kids to be good (6 / 4yr old boys) grab beers and go to shed.

Plated nuts and bolts not ready until next week... so hmmm install bearings in swingarm etc. oh and clean stuff.

mental note... use grease.


Installing swingarm bearings... socket sets are great..



used my press to install other bearings..





Again nice to have a socket set with multi sized bearing inserters...

also fitted steering head outer races... heat gun and freezer... no problem.





All done for the night... only took about 3hrs today..!



Metal note... NEVER tell wife about new things on my bike... always say.. look how they shine after a good clean... dam arn't I clever...

Mental note 2... always hide empty beer cans... 8 cans in 3hrs looks bad.

Mental note 3.... don't leave hacksaw blades that look like they may have been used for spotting on the bench... wife is very suspicius... she may not belive that they are used for shims ...

[cheese]

Coming along nicely! Makes me thing I should clean my bike or something.....

[Blagger]

"Mental note... NEVER tell wife about new things on my bike.."

No.3 Lies that women tell - "..oh this? I've had this dress forever"


touche

[marks]

awesome thread

more please

[cambocambo]

the frame looks great. what did you do to the swingarm is that a powdercoat?

[Arronduke]

The swingarm is also powder coated.
frame, subframe and swingarm cost $160 from memory and that incluided being sand blasted.

very pleased with the results.

[Arronduke]

"Mental note... NEVER tell wife about new things on my bike.."

No.3 Lies that women tell - "..oh this? I've had this dress forever"


touche

Your not wrong... I could have a garage sale and sell some of the stuff from the kitchen and wardrobe to fund some bits but I think I would be sleeeping in the shed..

[morg_nz]

Your not wrong... I could have a garage sale and sell some of the stuff from the kitchen and wardrobe to fund some bits but I think I would be sleeeping in the shed..

just wait till you have been dragged along shopping so many times you can actually say "no you dont need that - you bought that last year and have not worn it yet"

i often think if i put price tags on the stuff in the missus' wardrobe and presented it to her she wouldnt realise it was her and buy it back off me (to fund motorbike stuff of course :-) )

[grantman]

Its looking very clean and shiny
Is it going to get dirty?

Your KX250 was the cleanest bike of our group at the Raglan Campout.
Only because you were too scared to ride it in the mud.

When is it going to be up and running ?
Graham brought his CRF450 with the main goal of spraying you with mud!!!

Cheers

[Arronduke]

Mr Grant... dirt... hmmmm there was good reason for my bike not gettin dirty... it was not muddy. heee.

Good score today... adjuter screws in the swingarm, tank rubber support and airbox mud flap ... deal of the centry... thanks Bart.

ordered front and rear wheel seals.. 5mm wide.. at best i could do after market was 6mm wide... but real ones cost $44 each for rear and $22 each for front... $132 for seals... WTF. Got bearings for $15... cleaned original seal and they are mint... and now used.

run out of camera... had to take box shoots of the missess....

[Arronduke]

Got all my nuts and bolts back from the platers this week... looks good.
$50 for getting everything plated.

Started putting the front end togeather this week. New wheel bearings added and reused the wheel seals as the cleaned up fine.. and at a cost of $132 I did not need new ones as they are for dust and dirt only.





Time to start on te bottom end ...

[Arronduke]

We are re-decorating the house... this cost money.
I have to tell the wife.... "don't spend to much on this as we have spend a fortune" .. sort of I think...(shit).. its paint, gas hob and a few down lights so far oh and new curtains for the lounge... so to be honest its FA...so far... all the paint has been on my company account and I have to pay it out of my next pay... and I am paid monthly. Hech reason for budgeting... that's 12 pay days a year!!!

BUT I say.. "the credit card is getting up"... why I hear.. I have spent little. "Look around I say this redecorating is expensive.. hell it adds up". While I am thinking.. shit there are three passels coming from over seas, this is not good. Mental note pay special attention to the mailbox.

That's two for the USA and one from Thailand.

Thailand... WOW.. mega cheap parts for my race bike... as they use the same motor and hot it up. I am talking forged +2mm piston $20 USD and a master cylinder for $35.. $3 for hand grips and service is out standing. SO long story short.. my new race bike has twin calipers and the master cylinder does not flow enough fluid for two calipers.. pull the lever to the handle bar.. nearly tee boned a dude trying to pass him in to a herepin corner on the inside as he took the faster outside line. Yep nearly tee boned him trying to stop. Add a few carb trumpets at different lengths for tuning.. handle bar grips x 6, quick throttle for a spear $9.

Heaven

http://www.akunar.com/MOTORCYCLE_GRIPS.htm

So that leaves two passels.. both from the USA.


http://cgi.ebay.co.uk/ws/eBayISAPI.d...EOIBSA:GB:1123
$97 + $47 shipping for a grad total $144 NZ. I think its not a bad deal. ( 1 x wheel seal $44 NZ ... what a rip, no wonder we buy from out side NZ.
Complete Gasket Set w/Oil Seals Kawasaki KX 250 92
and next was a new throttle.. not sure if this was such a good deal.. but I need one.'
http://cgi.ebay.co.uk/ws/eBayISAPI.d...EOIBSA:GB:1123
$54 landed.

[noobi]

What do you mean 1 wheel seal for $44, you can buy a whole front wheel bearing kit with seals for ~$25, rear for ~$28 from any bike shop in NZ. A seal is a seal (the rubber one, not the clubbing one) it doesnt need to come in a kawasaki bag

[Arronduke]

No shit..they are sealed bearings.. WTF.
The ones with Y are in stock at Kawasaki and the N is ex japan, all prices are including GST. Still happy with that order and I will backorder the parts not in stock,



Flanged nut – 92015-1259 x1 $3.07 Y

Airbox duct seal – 92160-1331 x1 $39.92 N

Front wheel seal – 92049-1204 x2 $44.47ea N

Rear wheel seal – 92049-1203 x2 $22.07ea Y

Dam expensive I say..

[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....