rebuilding a dirt bike

[TheHoneyBadger]

So for my senior project I am rebuilding an old 1980 Kawasaki KLX250. I am sure I will run into some problems along the way so what I wanted to know is if there is anybody on here that has experience working on older Kawasaki's that I would be able to contact later on for possible help. Thanks.

 

[LeeDoo]

I rebuilt a '73 KF(?) 175 back when I was 15. Just bought a Clymer manual and went to town. I had never done any mechanic type stuff before, but my Dad helped me out and we got the bugger running good. I'm sure you'll do well on that bike.

 

[heinracing]

you can pm if you run into any questions on your bike

 

[SAWYER]

like lee said, just make sure you have the manual and you should be fine

 

[Gimpster]

Be careful pulling the engine apart. Some of those older engines require gaskets like between the case halfs, when splitting the tranny case apart. These gaskets a lot of times are needed for propper gear shaft end clearance when assembled or the main and countershaft will bind. What I am getting at is many of the parts for these older units are discontinued. Even gaskets.
Beforehand make sure the parts you may need are available aftermarket because a Kawi dealer probably will not be able to help you out wih OEM replacements
I go through this every day while servicing older units

----- Gimpster -----

 

[justadude]

Great advice.

Be careful pulling the engine apart. Some of those older engines require gaskets like between the case halfs, when splitting the tranny case apart. These gaskets a lot of times are needed for propper gear shaft end clearance when assembled or the main and countershaft will bind. What I am getting at is many of the parts for these older units are discontinued. Even gaskets.
Beforehand make sure the parts you may need are available aftermarket because a Kawi dealer probably will not be able to help you out wih OEM replacements
I go through this every day while servicing older units

----- Gimpster -----

 

[motomikey]

when not to rebuild your bike

dirt rider mag. had a article of this name a couple months back meaning if you want to rebuild them after a certain point, you'll be in it way more-even for just parts, than a new one would cost

 

[Gimpster]

Pretty true unless you have an older bike parts source like Sudco. Most of the cost anymore is in labor

----- Gimpster -----

 

[Supplicate]

http://www.bikebandit.com
http://www.rockymountainmc.com
http://www.thumpertalk.com
http://www.advrider.com

just a few to get you started. Bike Bandit has the most OEM stuff in stock, Rockymountain MC has a bunch of hard to find aftermarket items (they keep some gaskets in stock you can't find anywhere else) and are extremely fast with shipping.

 

[TheHoneyBadger]

Thanks guys!

 

[TBWdracula2003]

2 strokes are so easy to rebuild its not even funny, unless your tranny is giving you probs dont split the cases, i had a 90 kx 250 and i tore it down and put it back together in a combined time of 3 hours

 

[Killerk]

^klx is a 4 stroke^

Valves are probably shot... Hopefully its not the same engine as the mojave 250... Soft valves and a brass bushing that wears