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  #51  
Old 02-21-2016, 05:40 PM
hadfield4wd hadfield4wd is offline
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Quote:
Originally Posted by shang View Post
I really like vintage Kawi's. Absolutely LOVE the purple! Great job!!

Thanks its been fun. My sons is getting a rebuild now.


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1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
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  #52  
Old 02-21-2016, 07:31 PM
shang shang is offline
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Quote:
Originally Posted by hadfield4wd View Post
Thanks its been fun. My sons is getting a rebuild now.
I'm doing a similar project for my boy. We are rebuilding from the crank up, his little KX60.
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  #53  
Old 02-21-2016, 08:32 PM
hadfield4wd hadfield4wd is offline
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Quote:
Originally Posted by shang View Post
I'm doing a similar project for my boy. We are rebuilding from the crank up, his little KX60.

Nice this is our second bike together. I Love doing it.
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Matt

1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
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  #54  
Old 02-22-2016, 10:04 AM
hadfield4wd hadfield4wd is offline
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OK final bike. This is my sons KLX300.

Sold his RM. We had fun building it together. And he had lots of fun on it.
Bye bye



He wanted something he could turn into a dual sport and since I have one and know all the pitfalls we decided on another KLX. So this is project number 2.

This one is a 1997. It?s bone stock (Except for the pipe), dirty, leaks a little and needs some maintenance. After selling the RM and buying this I had cash for the parts.





It will be getting:
A good cleaning
The free mods
Fork seals
Chain and sprockets
Tires and tubes
ACR retime
Idler gear
Star wheel
Shock rebuild
Brakes front and rear
Wheel bearings front and rear
Carb tuning

That?s at least the start.
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Matt

1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
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  #55  
Old 02-22-2016, 10:06 AM
hadfield4wd hadfield4wd is offline
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Rear shock rebuilt by D’Orazio Dyanomic Engineering.
Everything is done.

New tires and tubes as well.

Went with a Bridgestone M59 front and Maxxis M6001 Rear.

Went with 15/50 gearing.

I put the Moose handguards on that were on the RM.

He loves the bike. It handles great and the power is way more predictable than the RM.

This thing has a screwy starting process when cold.

Fuel on
Choke on
Hold throttle wide open
Kick 7 times

Let off throttle
Turn choke off
Kick once from TDC

Starts right up.

When warm just kick and it starts

Ended up replacing it with a new carb now it starts right up. I think there was something wrong, maybe a hairline crack, who knows.

Needs:
New seat foam and cover
Oil drain bolt is stripped(ish) leaking so I’ll drill and tap it to M12. Just need to pick up a M12 bottoming tap.

We’ll keep riding it. It’ll get dual sported this spring. Also we’ll be updated the looks as well.

Oil leak is fixed. Drilled and tapped to larger drain plug.

Well got the DOT tires. I really wanted the Motoz Eunduro IT, but I purchase from my local dealer and he couldn't get them for a couple of weeks and he had to place a minimum order. I know I can get them online, but I like to keep my money local even if it costs me a little more. I'm weird that way.


Anyway I went with the same front that is on my KLX Metzeler MC6 front and it's hard to argue with the Kenda Trackmaster rear. $60 and My friends have had decent luck with them.


__________________
Matt

1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
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  #56  
Old 02-22-2016, 10:08 AM
hadfield4wd hadfield4wd is offline
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So quick update. Did a kx fork swap on this. Used '92 KX250 forks. Swap right in the existing triples. New wheel bearing and using the kx front wheel as well. Had the forks serviced and bushings done at my local suspension guy. He does a great job.

We've done a bunch of dual sporting together and its been great fun.

There are some ongoing issues that are nagging me. Nothing major, but need attention. The timing chain is making noise. I measured according to the manual and it's out of spec. So I ordered a new chain and OEM tensioner. Also throwing a piston in. No telling how many hours are on this one.

The new forks are anodized blue and the frame is purple with old graphics and a yamaha seat cover. Also the previous owner welded the exhaust to the frame. Stupid. So I'll be fixing this and putting a new slip-on on.

Painting the frame black and going with newer graphics and a black gripper seat cover.

So time for an update. I didn't get a chance to do anything to the motor on this. Just adjusted valves and jetted the carb. Engine makes a little noise. Timing chain is out of spec and compression is a little low. Also my 17 year old son didn't like the purple.



I left for a work trip with him getting started.



The previous owner did a crappy job on some things. The exhaust was falling off and breaking so he tried welding it on.







I've got a "new-to-me" White Brothers pipe to go on that looks great. Getting rid of the old heavy mega bomb.

Getting real. Frame welding and painting to come. Updated graphics as well.





More to come.
__________________
Matt

1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
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  #57  
Old 02-22-2016, 10:10 AM
hadfield4wd hadfield4wd is offline
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Frame is ready to the blasted and painted.

New tab welded on for the exhaust.



New foot pegs.



Cam chain was way out of spec. Cylinder will go for a hone Monday its all out. May need resurfaced. Final judgement on that is pending.

Frame is off for blasting and painting.

The oil pump has to be removed because it keeps the cam chain from jumping off the crank. Stupid thing is held in with phillips head machine screws. Phillips heads have their places, but inside a motor is not one of them. I had to use my impact drive to get them out. I'll be getting some button head allens to replace them. Anyway here is Caleb working on it.

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And we are up to speed. This is exactly where it sits. Frame is off to be painted.
__________________
Matt

1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
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  #58  
Old 02-22-2016, 12:57 PM
hadfield4wd hadfield4wd is offline
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I've got a new piston to go in. I cleaned a took a look at the cyclinder. It's got a distinctive mark/groove right at mid-stroke. Looks like the bike sat at one point for a while and was stuck there. So it's off to powerseal for a nikasil recoat.



__________________
Matt

1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
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  #59  
Old 03-20-2016, 06:33 PM
hadfield4wd hadfield4wd is offline
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Still impatiently waiting on the jug. In the meantime I have put in new valves, guides and seals.

Here is the frame as of Thursday.



I get it Wednesday then hopefully reassembled quickly.
__________________
Matt

1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
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  #60  
Old 03-26-2016, 08:54 PM
hadfield4wd hadfield4wd is offline
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Location: Roanoke, VA
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Frame is ready.



Tapped out all the bolt holes.



New valves installed. Used a home-made valve spring compressor. 14mm deepwell with an access hole and a large c-clamp.





Head bearings and swing-arm bearings serviced. Swing-arm stripped and clear coated. I hate that Kawasaki paints their swing-arms.





__________________
Matt

1999 GG EC 250 Six Days
1999 Cagiva Gran Canyon
2001 Aprilia Falco
2001 Triumph Speed Triple for my 20 year old
2000 GG XC250 for my 20 year old
2003 Honda Rancher 350 for the wife
Reply With Quote
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