99% finished 2005 KX250 rebuild turned project bike

Lowe#90
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Lowe#90
Edited Date/Time 3/16/2021 3:09pm
Started off with the idea of just rebuilding my 2005 KX250 after it sitting in the garage for 8 years collecting dust, what thought would be a quick strip down check and rebuild has ended up turning into a full project build with the budget more than doubling what I first thought it would cost 🤦🏼‍♂️😂😂







As I started stripping it down it came clear to see that 8 years sat in the garage has done way more damage to it than I thought!
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Lowe#90
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Lowe#90 4/29/2020 2:02pm
4/29/2020 2:02pm
Stripped the engine and found nasty gunked up coolant. Plan is to replace every bearing and seal in the motor, also plan on having a local two stroke specialist port the cylinder and machine the head then jet and map up my JD ignition correctly, also having a complete new clutch basically entire new motor other than casing, transmission is being super finished also.










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bonseff
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bonseff 4/29/2020 3:17pm
4/29/2020 3:17pm
Its a very nice platform to start with.
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Lowe#90
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Lowe#90 5/2/2020 9:45am
5/2/2020 9:45am
bonseff wrote:
Its a very nice platform to start with.
Thanks, hopefully it should turn out good.
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Lowe#90
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Lowe#90 5/2/2020 9:47am
5/2/2020 9:47am
Some more progress with some vapour blasting with a home made blaster







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The Shop

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.kyle
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.kyle 5/2/2020 12:43pm
5/2/2020 12:43pm
Seeing the damage caused doesn't fill me with much confidence when I sort my bikes out as they've been sat for at least that long!

Can't wait to see the finished product though! I love those kx250's.
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Lowe#90
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Lowe#90 5/2/2020 4:06pm
5/2/2020 4:06pm
.kyle wrote:
Seeing the damage caused doesn't fill me with much confidence when I sort my bikes out as they've been sat for at least that long! Can't...
Seeing the damage caused doesn't fill me with much confidence when I sort my bikes out as they've been sat for at least that long!

Can't wait to see the finished product though! I love those kx250's.
Yeah it’s not good pretty everything on the bike is either seized or gunked up, I wondering if my coolant was so bad cause of a hole in the water pipe elbow out of the water pump cover if it had possibly got air in or maybe it has just corroded by its self over time.

Yeah the late model KX’s are so good can wait to ride it again.


Water pipe elbow with hole
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Lowe#90
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Lowe#90 5/4/2020 3:46pm
5/4/2020 3:46pm
FarleyMX25 wrote:
Can you post some pictures of your vapor blaster?
RockyRider wrote:
what he said! ^
Yeah I’ll get some pictures tomorrow when I get home from work, it was originally a shot blast cabinet that my old man turned into a home made vapour blaster with a pump in a bucket underneath it
Lowe#90
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Lowe#90 5/4/2020 3:50pm
5/4/2020 3:50pm
Some more progress, more vapour blasting and cleaning parts, also we had a engineering shop mod my pro circuit clamps to fit the 2stroke as they used to be for a KTM 450 but I am putting my pro circuit A kit forks in the bike so needed to right size clamps to go in to match.











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Lowe#90
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Lowe#90 5/6/2020 12:10pm
5/6/2020 12:10pm
FarleyMX25 wrote:
Can you post some pictures of your vapor blaster?
RockyRider wrote:
what he said! ^
It started out as a old shot blaster then drilled a hole for water tube as well as airline then have the bucket underneath with the pump in the mixture, either water and glass beads or water and aluminium oxide



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dalshire21
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dalshire21 5/8/2020 1:21pm
5/8/2020 1:21pm
I would highly recommend sending your head and cylinder to Pro Circuit, Mitch developed some great porting for that motor! Not enough heads and cylinders to go around for these bikes anymore to risk getting a shoddy port job done. There really is a science to it and Mitch came up with really great porting specs.
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Lowe#90
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Lowe#90 5/10/2020 2:34pm
5/10/2020 2:34pm
dalshire21 wrote:
I would highly recommend sending your head and cylinder to Pro Circuit, Mitch developed some great porting for that motor! Not enough heads and cylinders to...
I would highly recommend sending your head and cylinder to Pro Circuit, Mitch developed some great porting for that motor! Not enough heads and cylinders to go around for these bikes anymore to risk getting a shoddy port job done. There really is a science to it and Mitch came up with really great porting specs.
I’d love to send it to pro circuit but unfortunately I’m on the other side of the world, the guy I’m taking it to has been at it a long time and is well established especially in the karting world they have a good few world records in karting so he is well clued up on what he’s doing.
Lowe#90
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Lowe#90 5/10/2020 2:39pm
5/10/2020 2:39pm
A little more progress, I got the frame and swing arm back from the powder coaters, got new bearing fitting in and got the modded pro circuit clamps in and my pro circuit A KIT showa forks











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mattyhamz2
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mattyhamz2 5/10/2020 2:46pm
5/10/2020 2:46pm
Nice! Love seeing the 03+ KX250 builds. Not enough of them around. My dad still has his 05. That bike is a blast to ride.
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Lowe#90
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Lowe#90 5/13/2020 2:32pm
5/13/2020 2:32pm
mattyhamz2 wrote:
Nice! Love seeing the 03+ KX250 builds. Not enough of them around. My dad still has his 05. That bike is a blast to ride.
Thanks and yeah it’s crazy to think a 15 year old bike can still look as good as they do in this day an age and they are so fun to ride just so light and flick able you can put them anywhere you want can’t you
Lowe#90
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Lowe#90 5/19/2020 1:45pm
5/19/2020 1:45pm
Progress has slowed a little now I’m back in work full time after the lockdown business but some more parts arrived and got some more cleaning and a little polishing done, new bars and radiators on








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Pit Row

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Titane
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Titane 6/4/2020 10:18am
6/4/2020 10:18am
Shame to pull those Ktm A kit fork on kawi (those are unicorns 😍)
But I’m sure it will look fantastic !
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Lowe#90
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Lowe#90 6/6/2020 4:02pm
6/6/2020 4:02pm
Hitthedirt365 wrote:
Man! You got some crazy project out there!!! Respect!
Thanks man, it’s taking longer than I wanted but will hopefully be worth it in the end
Lowe#90
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Lowe#90 6/6/2020 4:06pm
6/6/2020 4:06pm
Titane wrote:
Shame to pull those Ktm A kit fork on kawi (those are unicorns 😍)
But I’m sure it will look fantastic !
Yeah you don’t see many A KIT Showa’s about for KTM’s but these will go straight back in a KTM if I need them to as I’m going to run the KTM axle, wheel and brake
Lowe#90
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Lowe#90 6/6/2020 4:09pm
6/6/2020 4:09pm
kieran_macca wrote:
Sick build. Those forks look unreal!
Thanks and yeah don’t look bad to say I’ve had them for 6 years there’s not really much wear marks on them
Lowe#90
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Lowe#90 7/30/2020 1:20pm
7/30/2020 1:20pm
Djohnson672 wrote:
What radiators are those?
Sorry for the slow response not had much time to do anything since being back at work after lockdown. They are some cheap one off 24mx.co.uk they look pretty good but time will tell if they are any good.
Lowe#90
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Lowe#90 7/30/2020 1:26pm
7/30/2020 1:26pm
Progress has been super slow but managed to get a little done. We superfinished the gearbox at home, found a brand new pro circuit pipe which are getting hard to come by at the moment in the UK. Also a super trick front number plate bracket top and bottom which also incorporates a steering to be able to run the KTM pro circuit clamps with the modern 2020 KX250 plastics, all designed and 3D printed by my old man at home.










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cdoggy81
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cdoggy81 7/30/2020 7:53pm
7/30/2020 7:53pm
Awesome build! My last kx250 was an 05 as those were great bikes (05-07). Keep up the good work!
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Lowe#90
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Lowe#90 8/28/2020 3:43am
8/28/2020 3:43am
FarleyMX25 wrote:
How did you do the super finishing?
we have a small tumbler at home it took a while longer to do our selves with it being a small one started with a courser media then finished them off with a polishing media
Lowe#90
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Lowe#90 8/28/2020 3:44am
8/28/2020 3:44am
cdoggy81 wrote:
Awesome build! My last kx250 was an 05 as those were great bikes (05-07). Keep up the good work!
thanks, and they sure are I can't wait to ride this once I'm done and can't wait to feel how light an flickable it is to the modern 450's

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