Got a mid-'90s smoker you're thinking about bringing back to better-than-new condition? Oh, do we have an example for you with our latest project bike, a 1996 Kawasaki KX250.
While it's easy to love the old-school aesthetics of the 1996 KX250, as to some it's the "golden age for the Kawis", you have to quickly acknowledge the challenges in rebuilding one of these '90s two strokes. Over the course of the 25 years or so since it rolled off the assembly line, the components on this bike haven't been well taken care of and bring about a bit of a challenge to restore to full working order.
(Click play to watch this feature)
One of the primary obstacles encountered during the restoration of the '96 KX was the bike's practically unusable suspension. Jay had to piece together various components from multiple forks and shocks, just to achieve a functional set. Luckily, the crew from Race Tech is also well-versed in crazy restoration projects such as this and we're able to source some of the components needed. Along with the know-how and settings to bring this set back from the dead.
To restore the bike's engine back to its glory days, Jay enlisted the help of Brad from Parapros and Sano Metal Finishing. Together, they disassembled the engine, cleaned the components, and utilized a few different brands during the assembly process. Such as a ProX rod kit, Wiseco piston, and ProX main bearings. Luckily, the cylinder was in decent shape and didn't require extensive repairs. While no significant performance modifications were made, attention was given to reliability and the replacement of the worn-out parts. Speaking of the engine rebuild, honestly, the amount of parts that ProX had for this bike is impressive. Make sure you check out the parts list at the end of the article to see all the goodies they had available for this 25-year-old machine.
Throughout the restoration process, Jay encountered difficulties in sourcing certain parts due to their limited availability. This challenge was especially evident with the airbox and the exhaust pipe, for which suitable replacements were not readily accessible. Creative solutions became a bit necessary, such as patching up and basically rebuilding his own airbox. Thanks to brands such as MX Plastics, Decal Works, San Diego Powder Coating and MotoSeat...it wasn't too hard however to get the bike looking better than it did off the showroom floor.
With the bike fully rebuilt, we took the bike to the track for testing for a bit. While components like the ODI bars and grips, modern seat cover, IMS foot pegs, and other components provided a familiar riding experience...the bike's overall performance still falls slightly short of modern standards. Where this bike shines is in the nostalgia or sentimental value, bringing joy into the moment, rather than the top-of-the-line performance we're accustomed to with the latest and greatest. She's not a main track full-send ripper, but was a blast on Cahuilla's Vet Track blowing up burns, throwing some old-school style off some tables, and just reliving the moment.
Conclusion: The restoration of this 1996 KX250 illustrates the challenges and considerations involved in reviving vintage motorcycles. While the process can be rewarding, enthusiasts should be mindful of the limitations of older bikes and carefully assess the condition of critical components. If you can strike a balance between nostalgia and practicality, you'll enjoy the unique experience of resurrecting a classic machine. Does it make financial sense to rebuild one of these old smokers? Not always...and definitely not in this case. But for many, you can't put a price on nostalgia and passion.
Wiseco Performance Products
www.wiseco.com
737M06640 | Racer’s choice piston
WPP3010 | Clutch basket
CPK033 | Clutch pack kit
Pro X Racing Parts
www.pro-x.com
03.4309 Connecting Rod Rebuild kit
23.CBS43087 Main bearings & Crank seals
42.4300 Cranks seals
55.10552 Carb rebuild kit
53.110036 Throttle cable
53.120003 Clutch cable
57.4312 Water pump rebuild kit
17.4392F Clutch basket
18.4392 Clutch inner hub
18.P4392 Clutch Pressure plate
23.S110079 Front wheel bearing
23.S112023 Rear wheel bearing
26.710028 Front wheel spacer kit
24.110023 Steering bearing kit
37.63005 Front brake caliper rebuild kit
37.63028 Rear brake caliper kit
37.910002 Front master cylinder rebuild kit
37.910007 Rear master cylinder rebuild kit
07.FS23080 Front sprocket
07.RA42080 Rear sprocket alloy
07.RS42080R Rear sprocket steel
07.SBSM825 Rear sprocket bolt kit
07.RC520120CG MX Chain gold
26.640015 Counter shaft seal kit
33.0001 Upper & lower chain roller
26.210043 Swing arm bearing kit
26.110036 Swing arm linkage bearing kit
Cometic Gasket
www.cometic.com
Engine gaskets
Cranks by Andrew Langston
@mxandrew1118 (Instagram)
Crankshaft rebuild with ProX rod kit
FMF Racing
www.fmfracing.com
Fatty exhaust
Shorty Silencer
Dunlop Tire
www.dunlopmotorcycle.com
MX33 front
MX33 Rear
Klotz Synthetic Lubricants
www.klotzlube.com
R-50 Two-Stroke Pre-Mix & Chemicals
Faster USA
www.fasterusa.com
Complete Wheel Build from stock hubs
Uni Filter
www.unifilter.com
Two-stage Air Filter
DeCal Works
www.decalmx.com
Semi-Custom Graphics kit
Preprinted number plates backgrounds
UFO Plastic
www.ufoplasticusa.com
Full Flo Green Plastic kit
Mud Flap
Moto Seat
www.motoseat.com
Custom Seat Cover
Works Connection
www.worksconnection.com
Hour Meter and Mount
Stand
Front Brake Rotating bar mount
Steering Stem nut
Brake Reservoir cap
Elite Clutch Perch Assy
Oil Filler plug
MotoTassinari
www.mototassinari.com
V-Force Reed Cage
ODI
odigrips.com
MX V2 Lock On Grips
Champ Bars
Race Tech
www.racetech.com
Suspension Re-Valve and set up
Galfer USA
www.galferusa.com
Front and Rear rotor
Brake line rear
Brake line front
Brake pads front and rear
Specbolt Fasteners
www.specbolt.com
Engine and Plastic complete bolt kit
Sprocket Bolt kit
IMS
www.imsproducts.com
Foot Pegs
San Diego Powder Coating
www.sandiegopowdercoating.com
Sandblasting, powder with super-durable clear, and “race prep masking’
Sano Metal Finishing
www.sanometalfinishing.com
Vapor Honing & Cerakoting
Jay Clark/DBTV bike builder
Parts to buy RM ATV/MC -DBTV Shopping
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Rocky Mountain ATV/MC Shopping
RM ATV/MC -DBTV Shopping
7/13/2023 5:13pm
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