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Re: 2006 KX250F Rebuild
Posted: 07:41 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 07:44 pm Feb 21 2022
by SS109
Wow!
Re: 2006 KX250F Rebuild
Posted: 07:47 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 07:50 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 07:55 pm Feb 21 2022
by Slick_Nick
Cams installed, valve clearances set, the engine was timed, and turned over beautifully! It had lots of compression!
Shifter on, new sprocket, and new OEM case saver and guard were installed to replace the busted old ones.
Now, earlier, I had made an error, in that I installed the clutch plates (in my opinion) backwards. Since they have that scallop, I figured it better to have the sweep going back in the direction of rotation, so the oil kinda "flings" from inside to outside. I asked rocky mountain about this, and their response was that it didn't really matter, but it made me feel better. No matter anyways, as I had to pull the cover off to install the sight glass that had shown up at this point. This photo shows the CORRECT orientation of the clutch plates.
The finished product!
Re: 2006 KX250F Rebuild
Posted: 08:39 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 08:45 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 08:48 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 08:54 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:02 pm Feb 21 2022
by Slick_Nick
Lets take a break from things clean and shiny for a moment, and tear into the Enzo forks. The oil was disgusting! I also drilled out the peening so I could remove and replace the inner cartridge seals.
I didn't like the idea of using that wrench pictured above to hold the damper rod on reassembly, so I went to the mill and quickly whipped up a damper rod holding tool out of some scrap aluminum.
Like the shock, I kept detailed notes on all of the Enzo modifications to the base valve, and midvalve. I also noted that they had changed the inner cartridge pressure springs to 1.9's from the stock 1.4's. I went back to stock valving for now, again keeping detailed notes. I delayed reassembly at this point, because I realized the fork springs were just a touch too soft for my weight. They were different in each leg, but basically stock stiffness. I searched high and low for springs, none of the vendors had the .47's in stock. So, I decided to order them right from Kawasaki. They were about a week out however, so I set the fork components aside for now.
Re: 2006 KX250F Rebuild
Posted: 09:08 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:14 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:19 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:22 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:27 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:32 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:38 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:51 pm Feb 21 2022
by Slick_Nick
At this point, the bike was basically "done" aside from the plastics. I like leaving the installation of the plastics until the very end, because in my opinion, it's the most satisfying part of the entire build. Its where the whole bike really comes to fruition. Not to mention, filling fluids like coolant and oil can sometimes be easier without plastics in the way. I filled the bike with oil, coolant, made sure the brakes were bled and responsive, and gave it about a half a tank of race gas. I opened the petcock, and made sure the carb filled without overflowing. We were ready for the first start essentially.
Except, I walked away. I wanted to make sure I double and triple checked everything, so I went and had some lunch. When I came back, I made sure there were no leaks, double checked everything again, and started installing the plastics. The hardware that came with the bike was okay, but I had ordered a bolt plastic hardware kit anyways for a tiny bit of bling. Made sure to install the heat shield under the right number plate too!
And that was that! I can't fathom the amount of hours that I put into this bike, but it was so worth it.
After a few kicks, it roared to life! I got the idle dialed in, and after letting it warm up fully, I wanted to seat the rings with some moderate throttle runs up and down the street. Hope I didn't piss the neighbours off too bad!
Re: 2006 KX250F Rebuild
Posted: 09:57 pm Feb 21 2022
by Slick_Nick
Re: 2006 KX250F Rebuild
Posted: 09:58 pm Feb 21 2022
by Slick_Nick