Author Topic: 1978 Kawasaki KL 250 (Read 3704 times)

BenelliSEI · « **Reply #50 on:** November 02, 2023, 02:35:51 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.

I like it! Could you cut 3 or 4” off the end of the tailpipe and bring it all forward a bit?
We took the last pipe section out of this one and it looked much better! It just went too far back.

Kelly E · « **Reply #51 on:** November 02, 2023, 03:10:28 PM »

I figured that since it's a thin walled street bike muffler it won't last too long with a beginner rider.

If I still can't get a real system from Musket Muffler I'll buy a smaller shorter universal muffler.

BenelliSEI · « **Reply #52 on:** November 02, 2023, 06:34:32 PM »

Good plan!

Kelly E · « **Reply #53 on:** January 04, 2024, 04:16:32 PM »

Today we finally did something else to the KL 250. We got the throttle cables cleaned out, lubed up and installed. Tomorrow hopefully I can get the gas tank sorted out. After that we can try to get it woke up from 16 years of sitting in the last owner's dining room.

grcamna2 · « **Reply #54 on:** January 04, 2024, 06:00:56 PM »

Carson's going to like that KL250.

BenelliSEI · « **Reply #55 on:** January 04, 2024, 06:02:03 PM »

I like it too!

BallAquatics · « **Reply #56 on:** January 05, 2024, 08:01:33 AM »

What a cool thread Kelly. When I was 13, Pop brought home my first motorbike... it literally shaped the course of my life.

Kelly E · « **Reply #57 on:** January 25, 2024, 04:58:04 PM »

Quote from: BallAquatics on January 05, 2024, 08:01:33 AM

What a cool thread Kelly. When I was 13, Pop brought home my first motorbike... it literally shaped the course of my life.

Thanks buddy.

That's the plan, he'll learn on this and I already have his road trip bike. It's an 84' Honda VF 700S Sabre with the sport touring package. He'll be 15yo next month when I turn 65yo. I have to live long enough to see him graduate high school and take some road trips with me. I already got to see the girl graduate in 21'. I've been stage 4 prostate cancer since 15' so I'm living on borrowed time.

Today I worked on removing the fibreglass resin the PO tried to line the tank with. It's lifting because he coated it when the tank was dirty. I.made a tool to scrape it out but I wish I had something to dissolve the resin with. I have acetone that helped some so I guess I'll try round 2.

grcamna2 · « **Reply #58 on:** January 25, 2024, 05:44:56 PM »

I like that Carson's going to get your Sabre 700S

.
I don't envy you for needing to remove fiberglass from inside the tank;I think Acetone will do a lot but the best is Ketone,(outlawed here and lots of places)it'll melt that stuff.
I recommend a special fresh air respirator though.

Kelly E · « **Reply #59 on:** January 25, 2024, 07:36:03 PM »

Quote from: grcamna2 on January 25, 2024, 05:44:56 PM

I like that Carson's going to get your Sabre 700S .
I don't envy you for needing to remove fiberglass from inside the tank;I think Acetone will do a lot but the best is Ketone,(outlawed here and lots of places)it'll melt that stuff.
I recommend a special fresh air respirator though.

I'll see if I can find some Ketone.

Kelly E · « **Reply #60 on:** January 27, 2024, 03:26:15 PM »

Well I spent two days scraping and scratching with a tool I made from 2mm spring steel rod trying to get out all of the loose stuff and chunks of fibreglass resin. Today it's finally filled up to the brim with EvapoRust for the next few days. No sign of leaks, I'm keeping my fingers crossed.

I also managed to get the gas cap apart so I could clean out all the vent passages so the bike will run further than the bottom of the hill.

grcamna2 · « **Reply #61 on:** January 27, 2024, 06:28:03 PM »

A lot of work to remove some tank liners.

Kelly E · « **Reply #62 on:** January 27, 2024, 07:36:24 PM »

Quote from: grcamna2 on January 27, 2024, 06:28:03 PM

A lot of work to remove some tank liners.

This wasn't a real tank liner, the PO attempted to line the tank with fibreglass resin. It's been a royal pain in the ass. $:-\$

Some people should have their toolbox welded shut and their fingers busted.

Kelly E · « **Reply #63 on:** January 31, 2024, 07:47:24 PM »

Today we finished cleaning out the gas tank. We poured out the EvapoRust and did about 10 diesel rinses. It appears that the EvapoRust helped lift the fibreglass resin from the inside of the tank. That's why it took so many diesel rinses to get the remains of the resin out. I think we got it all out of there, I'll get a better look tomorrow.

Kelly E · « **Reply #64 on:** February 14, 2024, 12:45:08 PM »

Well the tank hasn't sprung any leaks and most of the rust is gone. There's a few spots that are still sealed to the tank with the fibreglass resin but they shouldn't be an issue. We might try to fire it up this weekend if it doesn't snow.

BenelliSEI · « **Reply #65 on:** February 14, 2024, 04:44:01 PM »

Be nice to see it all back together!

Kelly E · « **Reply #66 on:** February 14, 2024, 06:36:23 PM »

I spoke too soon, I got more fibreglass resin crap out of the gas tank today.

grcamna2 · « **Reply #67 on:** February 14, 2024, 07:11:13 PM »

Quote from: Kelly E on February 14, 2024, 06:36:23 PM

I spoke too soon, I got more fibreglass resin crap out of the gas tank today.

I'm glad for you that it's finally releasing.
I never saw fiberglass used in a steel motorcycle tank,so far.

RAFster122s · « **Reply #68 on:** April 14, 2024, 03:25:03 AM »

Quote from: Kelly E on January 25, 2024, 07:36:03 PM

Quote from: grcamna2 on January 25, 2024, 05:44:56 PM
I like that Carson's going to get your Sabre 700S .
I don't envy you for needing to remove fiberglass from inside the tank;I think Acetone will do a lot but the best is Ketone,(outlawed here and lots of places)it'll melt that stuff.
I recommend a special fresh air respirator though.

I'll see if I can find some Ketone.

MEK methyl ethyl ketone

Causes cancer and can give you a nasty headache…
If you find it, buy extra as just matter of time before it isn’t available. Just store it in a metal can for the metal can. That way if it rots through the can you won’t lose it…
Had a can of berrymans, the old stuff you haven’t been able to buy for over a decade and abd rusted through the bottom and lost it all. At least it was outside, cannot imagine what would have happened had it been inside…

Kelly E · « **Reply #69 on:** April 24, 2024, 04:22:00 PM »

Yesterday we dumped out the EvapoRust after a 6 week soak. Got a whole bunch of the fibreglass resin out again. A lot of the resin came off the sides and top of the tank, it came out in big sheets. Still no sign of any leaks so I have to wonder why it was put in there.
I strained the EvapoRust and might put it back in for a while. One of these days I'll win and get the gas tank cleaned up and back into service.

grcamna2 · « **Reply #70 on:** April 24, 2024, 04:37:34 PM »

Quote from: Kelly E on April 24, 2024, 04:22:00 PM

Yesterday we dumped out the EvapoRust after a 6 week soak. Got a whole bunch of the fibreglass resin out again. A lot of the resin came off the sides and top of the tank, it came out in big sheets. Still no sign of any leaks so I have to wonder why it was put in there.
I strained the EvapoRust and might put it back in for a while. One of these days I'll win and get the gas tank cleaned up and back into service.

The KL250 tank has been giving you fits.

Kelly E · « **Reply #71 on:** May 13, 2024, 12:38:15 PM »

I finally got all of the fibreglass resin out of the gas tank. Just got done coating it with 2 stroke oil and yesterday I got the new battery filled and charged.

grcamna2 · « **Reply #72 on:** May 13, 2024, 11:49:54 PM »

Quote from: Kelly E on May 13, 2024, 12:38:15 PM

I finally got all of the fibreglass resin out of the gas tank. Just got done coating it with 2 stroke oil and yesterday I got the new battery filled and charged.

Close to a start ?

MauiK3 · « **Reply #73 on:** May 14, 2024, 07:45:38 AM »

Tank looks clean!

Kelly E · « **Reply #74 on:** May 14, 2024, 08:20:42 AM »

Getting close, I have to get the clutch installed on the 81' GS 1100E first before I put the KL 250 back on the lift.

News:

Author Topic: 1978 Kawasaki KL 250 (Read 3704 times)