Here we go, ever buddy! I have been fittering away time and energy on my hopeless KDX 250, and I even took some pictures along the way.
The last time I wheeled it out, I tried to install the new throttle cable I ordered so long ago. Well, we ran into a problem right off the bat. It seems the new cable is not compatible with the twist throttle that is currently on the bike. The new cable looks perfect, but the threads that engage the throttle housing are incorrect. I bodged it together just to blip the throttle a few times, but it was obvious that it wouldn't work. Plus, the carb I'm using didn't have the brass adjuster barrel that the cable clips into. What to do? Off to eBay! A search for KX throttle assembly netted a ratty used example with usable cable AND brass barrel. Sweet. On she goes.
Next, the clutch cable. I pulled out the cable I ordered also so long ago, and proceeded to hook it up. Another problem: a full 4 inches too short! No routing whatsoever could get it up to the lever (unless I routed it through a conveniently placed wormhole, I suppose, but I'm fresh out of those). EBay to the rescue again! This time, a NOS cable did the trick. However, I have the cable at max slack, and it's just BARELY enough to connect to the lever. It could be the high zoot plastic perch/levers the bike has are diffent dimensions than stock? Anyhoo, the clutch feels normal at the lever, just no free play. We'll see when i get the chain on and can buzz around the yard a bit.
I got a new brake cable all lubed up and installed. This is the ONE cable out of three that I originally ordered that actually worked! Batting .333! And I have to say that I don't expect very good stopping power from this brake--feels like I'm squeezing a piece of oak with a pair of channel locks.
At least it lets me squish the forks up and down in the garage.
Hmm...Let's see... I also managed to update the looks about twenty years with the addition of a well-stickered front fender from my 2003 Hybrid bike. It was just sitting in a box waiting for the Acerbis replacement fender I'm using to break, which it never does, so why not slap it on ol' Rusty? Sho nuff!
What next? Well, I had a perfectly new set of All Balls rear wheel bearings staring up at me from my almost empty parts box, so why not? First, I assembled all the needed tools for the job.
Ratio Rite? Check Multimeter and clip leads? Check. Random screws? Check. Defective ZX600C CDI? Check. Q-tip? Check. Giant, surprisingly useful whacking tool? Check-a-roo. (If it tells you anything, this was the LEAST cluttered section of my work bench, so was thus suitable for photography)
So here's an interesting little aside. When I got the first bearing out (brake side), it unsealed a dead space inside the hub between the axle tube and hub casting. I'm pretty sure the air that came out was original 30-year-old Japanese atmosphere. And wow did it stink. Must have been a high smog day in Kobe 30 years ago.
I took the opportunity to pack the new bearings with extra grease. I'm glad I did, because two of them hardly had any in them at all.
Bearings installed, wheel back on, and all is nice and tight. While putting the wheel on, I noticed the spark arrestor is still intact in my silencer, despite the end cap being removed and missing.
What next? Airbox, of course! Early on in the process, I ordered a second air box from eBay so I could get the cage that goes inside the air filter. I'm still using the box the bike came with, plus its cover. It was missing some fasteners, but with the help of a fastener kit (I'm loving it), we're in business.
All the holes in the cover get covered up by the side panel.
I was also a bit concerned that the choke knob on the Keihin carb would be blocked by the airbox, as it would be on my '87 200, but no problem there.
It's starting to look like something I could actually ride soon!
A few random pictures. I found the rear side panel bolt is broken off in the frame. That'll be a fun hour or so.
My pipe mount will need some very special jiggering to make work.
And I'll have to get another of these chunky bolts to keep old kicky in place. I had to do this for another KDX I had, and instead of buying the $8 bolt from Kawi, I got a $2 bolt at Lowes that was half an inch too long. I hacked it down and dressed the threads, and it worked great. $5 well saved!
That's it for now. I'll be buzzing this thing around the yard before you know it! (All the while still putting off doing my fork seals...)