Author Topic: 1978 Kawasaki KL 250 (Read 4465 times)

Kelly E · « **Reply #25 on:** May 04, 2023, 04:06:42 PM »

Today we finished sanding the frame. After Paul left I made and welded on a piece to strengthen the rear rock guard mounting bracket. It was just a piece of strap with a hole in it. I added another piece to the back edge so it doesn't just bend upward when it takes a hit.

Kelly E · « **Reply #26 on:** May 05, 2023, 01:47:10 PM »

Today I made the rest of the rock guard. I need to put the motor in one more time to make sure the drain plug access hole is in the right spot.

grcamna2 · « **Reply #27 on:** May 05, 2023, 01:50:29 PM »

Quote from: Kelly E on May 05, 2023, 01:47:10 PM

Today I made the rest of the rock guard. I need to put the motor in one more time to make sure the drain plug access hole is in the right spot.

That one at the bottom will certainly protect the engine cases.

BenelliSEI · « **Reply #28 on:** May 05, 2023, 02:38:32 PM »

Nice work!

Kelly E · « **Reply #29 on:** May 19, 2023, 02:59:37 PM »

Today we got the frame painted. We painted it in the new shed on the back of the shop. It was way easier to see what I was doing and the paint didn't turn to dust before it hits a nearby frame tube like it does in the direct sunlight.

BenelliSEI · « **Reply #30 on:** May 21, 2023, 05:27:50 PM »

Looking good! This will be a fun ride!

Kelly E · « **Reply #31 on:** July 23, 2023, 09:55:47 AM »

Yesterday we installed the motor in the frame and assembled the triple tree. I had to enlarge the hole in the rock guard I made on the bottom. The hole for the drain plug was too small and too far back. After that I had to touch up the bed liner.

grcamna2 · « **Reply #32 on:** July 23, 2023, 10:35:16 AM »

Progress

BenelliSEI · « **Reply #33 on:** July 23, 2023, 11:10:09 AM »

Going to be a good bike!

RAFster122s · « **Reply #34 on:** July 23, 2023, 02:18:54 PM »

Is the son chomping at the bit for the bike to be finished?

Kelly E · « **Reply #35 on:** July 23, 2023, 02:37:08 PM »

Quote from: RAFster122s on July 23, 2023, 02:18:54 PM

Is the son chomping at the bit for the bike to be finished?

Sort of, he has a girlfriend now so he's "busy".

grcamna2 · « **Reply #36 on:** July 23, 2023, 04:43:44 PM »

Quote from: Kelly E on July 23, 2023, 02:37:08 PM

Quote from: RAFster122s on July 23, 2023, 02:18:54 PM
Is the son chomping at the bit for the bike to be finished?

Sort of, he has a girlfriend now so he's "busy".

I hope you get the passenger pegs on the bike.. for later.

Kelly E · « **Reply #37 on:** July 31, 2023, 03:04:54 PM »

Today I got a few more parts installed. I'd better get the wiring harness cleaned up soon, it's time to install it.

grcamna2 · « **Reply #38 on:** July 31, 2023, 06:15:43 PM »

The rear shocks look good.

Kelly E · « **Reply #39 on:** September 04, 2023, 03:44:09 PM »

Today we worked on rounding up decent hardware to put stuff back together. It was a hodge podge of hardware already so we dug into the stash and used what worked. I did a lot of trimming bolts to the correct length. Now there's quite a bit of Honda hardware on this Kawasaki.

BenelliSEI · « **Reply #40 on:** September 04, 2023, 05:00:09 PM »

That is looking very nice!

Kelly E · « **Reply #41 on:** September 19, 2023, 03:39:02 PM »

Today I got some stuff done on the KL250. The missing seal for the sprocket carrier came in so I installed it. Then I tackled the messy job of lubing all 7 of the control cables. I realized I needed to get the rear brake cable installed before the rear wheel just because it will be easier.

Kelly E · « **Reply #42 on:** September 30, 2023, 04:19:54 PM »

Today we got more done like the kickstand, exhaust pipe, rock guard, gauges, foot pegs, airbox and battery/electrical stuff. We took the front fender back off because I forgot to mask and spray the bottom side with bed liner.

We also got a few more bits and pieces ordered like handlebars and grips. I need to remove the gauges to blast and paint the guage/ headlight mount. CRS(can't remember #$%*) strikes again.

grcamna2 · « **Reply #43 on:** September 30, 2023, 04:42:33 PM »

Kelly,this KL250 project is coming along well;I like the custom bend to the head-pipe.

Kelly E · « **Reply #44 on:** October 14, 2023, 01:42:43 PM »

Today we got the exhaust system finished. The muffler seems a bit long but we can find another one after the boy thrashes this one. I have everything else ready to install the headlight bucket and wiring. Then install the bar controls so I can put the headlight in. Also finish up the cable routing brackets and clean out the gas tank.
It's almost done and then I can go see how long the 30 year old tires last.

grcamna2 · « **Reply #45 on:** October 14, 2023, 01:55:54 PM »

Quote from: Kelly E on October 14, 2023, 01:42:43 PM

Today we got the exhaust system finished. The muffler seems a bit long but we can find another one after the boy thrashes this one. I have everything else ready to install the headlight bucket and wiring. Then install the bar controls so I can put the headlight in. Also finish up the cable routing brackets and clean out the gas tank.
It's almost done and then I can go see how long the 30 year old tires last.

Kelly,the custom exhaust you fabricated reminds me a little of a Kawasaki 1400 Concours style.
The bike is looking good.

Kelly E · « **Reply #46 on:** October 14, 2023, 02:59:08 PM »

Yeah it does have that potatoe launcher look.

That's what you get when building stuff from scrap.

grcamna2 · « **Reply #47 on:** October 14, 2023, 04:26:30 PM »

Quote from: Kelly E on October 14, 2023, 02:59:08 PM

Yeah it does have that potatoe launcher look.
That's what you get when building stuff from scrap.

The exhaust cannon

Got a 'Rad' look to it.

Kelly E · « **Reply #48 on:** October 22, 2023, 08:16:06 AM »

Yesterday we went through the handlebar controls to clean up the switches and get some fresh dielectric grease in them.

Kelly E · « **Reply #49 on:** October 29, 2023, 08:40:16 AM »

Yesterday we started to deal with the gas tank. There's no visible signs of it leaking but the PO tried to line the tank with what looks like fibreglass resin. It's already peeling and we got a bunch of it out with a long pick. Then we poured in some acetone and walked away.

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Author Topic: 1978 Kawasaki KL 250 (Read 4465 times)