Here goes nothing!

Discussion specific to the 1991 - 1994 KDX250 sold in the USA
CBHDMD
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Here goes nothing!

Post by CBHDMD »

Oh where to begin lol, this bike and i have some history to say the least, maybe I'll get around to some of the stories one day but for now I'll do a quick background to get up to where i am currently.

This awesome machine entered my family somewhere around 94 or 95 i believe. I would have been 12-13 and we had been riding offroad as a family for three or four years, mostly my dad, sister, and i, mom eventually got a quad and joined. Anyhow, i ended up in the kdx more than not and we bonded lol. I rode it until somewhere around '00 when i started riding quads more because that's what everyone else was on and it was easier to strap a cooler to.... I left for school around 01 and the kdx sat in my dads shed for the next eight years while i was on the other side of country. This did it no favors although i am lucky it fared as well as it did, and also lucky it didn't get sold (while i was away, parents divorced, new wife made dad sell all bikes and related things, i regret not convincing him to sell me his 220, but hindsight, past is what it is...) In 2009 I moved back east and reclaimed the beast. After clearing a mouse nest from the airbox, and carb boot and a thorough carb clean (although it should have been replaced) I got it back out in the woods and remembered how much fun it was. I don't know if it was the fact that i was trying to focus on my career or that i was spending most of my time on street bikes but the kdx was neglected... in '13 my wife and I had to relocate temporarily and I made a deal with a friend to look after, ride and enjoy the kdx as long as he didn't sell it. Well the hiatus took longer than planned as i should have known, but in 2016 we made it back east and i once again took possession of my kdx. Well as life goes, we bought a house and with go shed or garage, the kdx was put in a storage unit until further notice. I have plenty of other projects! I also don't know any other riders in the area yet and was low on motivation. Well my friends kids are out growing the cheap knockoff little bikes and getting into some real riders so i decided its time to do my poor kdx justice and give her the freshening she deserves.

So it begins. I am aware that this will be a build out of love, and I'm pretty sure that I'll easily invest more in the rebuild that when we bought the barley two year old bike lol. I'm OK with that.

The plan, new tires, wheel bearings front and rear, swingarm feels OK, new bars, grips and levers, steering head bearings, new expansion chamber and repack of the hockey stick, fork rebuild with gold valves, (may do springs eventually but I'm gonna do the rebuild and ride this summer as is) v force3 reeds, kx head gasket, replate and new piston, new crank seals and bearings, possibly plastics....i want to make it as right and tight as possible.

My challenges so far: unobtanium
Well i should have known with a limited production bike that I'd hit some snags. The biggest challenges so far are that i need a carb, i emailed Ron Black and was told they have nothing for me which leaves Lectron or replacing the stock pwk38. I'm still undecided as lectron can't help me until they get back to work after corona lockdown, so I'm starting to lean towards contacting sudco for a pwk....
Second, and perhaps bigger issue currently is that my shift shaft has gotten bent.... and apparently it was specific to this run of bikes. I am taking a gamble on one from a 88-92? Kx250, they use the same deal and visually look the same so when it arrives I'll know if it'll work or not, I'm guessing that the length may be my only issue, at which point, i may have to use the straight shaft and have it welded... not my first option but...

So currently i have the tires on, cases split, cylinder at millennium, and plenty left to do lol.


I'll try get some pictures up tonight.
'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
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bufftester
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Re: Here goes nothing!

Post by bufftester »

Welcome to the forums and good luck on the rebuild
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KDXGarage
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Re: Here goes nothing!

Post by KDXGarage »

Thanks for sharing the story! Good luck on the KDX250 build! I am looking forward to it.

Change the shock oil and grease the swingarm bearings.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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doakley
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Re: Here goes nothing!

Post by doakley »

Nice story and I completely understand the motivation. Thanks for sharing and good luck! Please let us see how you progress.
CBHDMD
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Re: Here goes nothing!

Post by CBHDMD »

Looks like most of the teardown pics I've taken with my phone are too large to post. While i try sort that, here is a carb pic showing the rodent damage. The overflow stand tube in the float bowl was also corroded and broken.
received_650764475655789.jpeg
received_650764475655789.jpeg (146.15 KiB) Viewed 13411 times
'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
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Re: Here goes nothing!

Post by KDXGarage »

WOOOOOOOOOOOWWWWWWW!
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
kdxsully
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Re: Here goes nothing!

Post by kdxsully »

Nasty little buggers.
I like turtles
CBHDMD
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Re: Here goes nothing!

Post by CBHDMD »

Ok, trying out a resize app.
Pictures comparing the KX250 and KDX250 shift shafts, got it installed and seems to shift OK on the bench.
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Attachments
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'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
CBHDMD
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Re: Here goes nothing!

Post by CBHDMD »

Cyl didn't look horrible imo except for this spot that looks like the plating chipped off? I was worried that it may be a crack that would need to be welded. I sent it to millennium for inspection and replate.
20200417_154652-1512x2016.jpg
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20200417_153058-1512x2016.jpg
20200417_153058-1512x2016.jpg (397.02 KiB) Viewed 13392 times
'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
CBHDMD
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Re: Here goes nothing!

Post by CBHDMD »

Here's my beauty not exactly a glamor shot but.....
Got the purchase info dug up, we bought it in 1996 for $1999 +tax
Hopefully i can dig up some photos from when we got it.
20200404_204710~2-1440x2015.jpg
20200404_204710~2-1440x2015.jpg (680.83 KiB) Viewed 13392 times
'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
CBHDMD
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Re: Here goes nothing!

Post by CBHDMD »

Oh, and this....
20200421_103321-1512x2016.jpg
20200421_103321-1512x2016.jpg (611.59 KiB) Viewed 13391 times
Sadly, i found two sets on ebay, both had the same right side top pin broken, and neither description mentioned it. Both said sets were in good condition. :doh:
I was able to find one used one unbroken.
Also found sellers selling one nos valve for $500... gouge much? Ugh.
'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
User avatar
KDXGarage
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Re: Here goes nothing!

Post by KDXGarage »

WOW!

See if papouch from Poland?? sells them on eBay.

I think that plating may have flaked off.

"Kevin's Racing Supply"... I remember buying some fork springs from there 15?? years ago.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
CBHDMD
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Re: Here goes nothing!

Post by CBHDMD »

This one here takes the cake.
Screenshot_20200503-105930_eBay.jpg
Screenshot_20200503-105930_eBay.jpg (653.54 KiB) Viewed 13375 times
I do see someone from the czech republic selling cnc ones for a reasonable price. I saved it in case i need any in the future.
'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
User avatar
KDXGarage
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Re: Here goes nothing!

Post by KDXGarage »

Yeah, some NOS sellers are asking for a fortune.

I think the guy I was talking about is indeed from the Czech Republic, "papouch" or something like that. He has been at it for a few years now.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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Re: Here goes nothing!

Post by KDXGarage »

Yes, he is papouch on TT.

https://thumpertalk.com/forums/topic/96 ... with-pics/

It's the same guy.
Thank you for participating on kdxrider.net. :bravo:
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Re: Here goes nothing!

Post by kdxsully »

That’s a bargain! :roll:
I like turtles
CBHDMD
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Re: Here goes nothing!

Post by CBHDMD »

Little update, haven't had a lot of time to work on the project, usually about four hours a week. Got an email from millennium last week saying that my cylinder failed final qc and had to go through the process again. Boo, but it's definitely not what's holding me up so.... as it stands, I've got the the tires mounted and bottom end back together. New carb came this week YAY decided to go with a pwk, #6 slide, CEL needle, 38 pilot and 158 main jet to start with, also got the reed block trimmed up to fit the v force reed cage.
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And my other exciting find
20200513_130315.jpg
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Biggest hurdle now is getting the motivation to tackle the forks, and get my reading done to see if i can even come up with the tools needed to do it. Other than that, i have to figure out if i can braze a couple broken aluminum bits, and start putting things back in order.....
'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
User avatar
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Re: Here goes nothing!

Post by KDXGarage »

Keep up the good work.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
CBHDMD
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Re: Here goes nothing!

Post by CBHDMD »

Fragile! Get the hammer and the crowbar.
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It's go time!
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So, it looks like they bead blasted the whole thing, (I'm not a big fan of bead blasting machined gasket surfaces but what's done is done, ) i feel like i need to clear coat or paint the outside now?
20200515_215658.jpg
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'92 KDX250 OG Ride
'00 KDX220R Daily Ride
'72 GT550 Project
'83 R100RT/S Peaceful Ride
'14 FXDB Loud & Fast Ride
Writing this, I've realized that all the bikes I own are discontinued..... guess they don't make em like they used to!
User avatar
bufftester
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Re: Here goes nothing!

Post by bufftester »

Also not a fan of blasting sealing surfaces. Some clear coat will help it stay clean looking quite a while.
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