Went with my No2 Grandson to Moonbi (20Km North of Tamworth) to pick up a 1986 Kawasaki KLR250D. The PO told me he had pulled the head and barrel off to find out why the low compression, then a few other bits to restore it and lost interest. The beer economy was still working so we gathered up all the boxes of bits and home for a look see. As usual with these kind of deals, 10% is missing, 20% is butchered and the rest needs a complete overhaul. Only major parts missing so far is the complete exhaust system. Plastics and wiring in one bin, engine bits in another, seat ripped, tank full of rust, etc. Head looks ok from this side. Intake cam has had an oil feed problem on one bearing and has lost the hardfacing from the lobe top. Will no doubt find lots of stripped threads and shagged bolts/nuts but so far nothing that cannot be fixed. All good learning for the next rider in line.
The PO found and brought over the exhaust today, thank you very much. Have the head disassembled and seats cut, exhaust valves are ok but the inlets are so worn away that the edge is paper thin and both are too small to regrind to fit in the seats. New valves are pricey (seems to have been a problem on this model) and seeing as how they are stuffed and cannot be used as is I thought about trying the old idea of building the faces up with the TIG. Can anybody recommend a filler rod suitable for the faces that can be reground back to original size?
I've seen videos of people using stellite rods and welding valve faces to increase service intervals, might be a good experiment
Have ordered two new valves as about the same price as a stellite rod, and no worries about upsetting the heat treatment of the valves. Had the frame and bits sandblasted last week and got them painted yesterday so the boys could make a start on re assembly today.
I found a video of someone rebuilding a burnt FZR1000 valve with stellite tig rod, I think I've posted it somewhere here - here's the post with the video - I recall researching which grade of stellite and I think it's down to #6 or #12 https://www.2fiftycc.com/index.php?threads/fzr-250-overbore-300.10253/page-2#post-118932
WHOOPS missed this post, out of interest where did you find a price for stellite rods - I've been researching many specialist [well in this country] alloy rod - Aluminium mostly, also stellite, but not much is coming up in Aus.
I ended up using some old Fenix 406 rods that I had and built up layers on the cam nose. I hand ground back to a similar profile as on the exhaust cam and finished on the belt sander. Looks good so we will see how it goes with some use. Boys have the head together, bore honed and washed but we are still waiting on the rings coming from US. Have been putting bits through the blaster, painting and hanging on frame ready for when we can get the engine together and in the frame. Have all electrics in and working, forks rebuilt with new seals and oil, new master cylinder, braided line and caliper rebuild kit fitted.
Haven't heard from the grandson I was keeping this for since 3rd October and today an aquaintence offered me good money for it so it has gone.
