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Project No 2 Grandson's KLR250

Discussion in 'Your 250cc Projects' started by Murdo, Oct 2, 2021.

  1. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    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.
    KLR250 013.jpg
    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.
    KLR250 011.jpg KLR250 010.jpg
    Head looks ok from this side.
    KLR250 020.jpg
    Intake cam has had an oil feed problem on one bearing and has lost the hardfacing from the lobe top.
    KLR250 015.jpg
    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.
     
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  2. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    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?
     
  3. Andych

    Andych Moderator Staff Member Premium Member Contributing Member

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    Have a look at 312 Stainless filler rod... it seemed to come up in a a quick search.
     
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  4. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    I've seen videos of people using stellite rods and welding valve faces to increase service intervals, might be a good experiment
     
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  5. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
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    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.
    Dylans 13th birthday 010.jpg
     
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  6. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    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
     
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  7. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    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.
     
  8. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Local welding shop wanted $76 for 500mm rod. Bought two valves for $79 delivered from USA.
     
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  9. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    One single rod?
    I know the stuff is expensive, but it's not that expensive...
     
  10. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    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.
    KLR250 014.jpg
    Have all electrics in and working, forks rebuilt with new seals and oil, new master cylinder, braided line and caliper rebuild kit fitted.
    KLR250 020.jpg KLR250 029.jpg
     
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