[JustinL]

I guess I am the sort of guy who can't get something in good shape.... .I always buy a project. Anyways, I won that "96 KLX 300." Won it for 613 bucks. I knew it wasnt a 300 because they wern't made until 97 and the panels matched a klx 250. So, I get down to pick up the bike, we check it over, point out that its not a 300, so the guy knocks of 100 bucks. I ask him if he'll take 500 and we are off. So far, I have comletely torn it down to the frame, painted it (not feeling that 90's purple) and started putting it back together. I am replacing all of the frame bearings. All I have left to replace now is the front wheel bearings and the swing arm bearings (should be here wednesday).

Heres what it looked like when I bought it;











The engine is seized. Pulled off the cluch and the transmission is good. It has a KX125 cluch (much better). From what I can see so far, the entire tranny engine (except the crank/rod) is in good shape, the case isn't completely split apart yet. Heres the problem;



The most I am out is 265 bucks, but I see them usually go for around 150 bucks on ebay. My friend works at Felber Race Engineering, and the owner said he'll help me rebuild the engine for the right amount of beer, So I should have a $1500 bike for ~950 bucks. So far, with all new bearings, paint, levers, and rebuilding everything, I have 700 bucks into it.


Here it is now (minus the engine which is behind it).

[Justin3]

So your engine is seized at the crank berrings which makes it had to spilt open the motor, I had the same thing on my friends old snowblower, I decided to soak the whole block in old motor oil over night and in the morning we flushed out the oil then my neighbor but a torch on the shaft after the oil fire went out it loosened.

[WoodButcher]

Nice job kiddo, Whatever you do try not to do this shit for a living. when ya get older and the bride gets long in the tooth you can still enjoy your "hobby"

[JustinL]

The only thing seized is the crank/rod. the crank will turn in the case. I can get one for 265 shipped. I pulled the engine apart tonight, All I need to do is figure out how to get the stator magnet off of the crankshaft and that will be pulled apart as well.

[JustinL]

I got the crank unsized, put everything back together and ran it... I could only get it to start by pulling it behind a truck at ~20mph and dumping the clutch, it ran for a total of around 40 seconds, then seized up again. I wont almost a completel engine for 20 bucks, So i should have it running for real in a little while.

[super_Chris]

The bike looks pristine. Good job. And I demand pics of the bike complete.

[JustinL]

well, here it is. The carb is WAY out of adjustment, but it runs. I think the compression ratio is 14:1. The engine seized up because I forgot to tighten the nut that holds the output gear to the crank shaft...

As it sits now:


The new cylinder and piston:


The nut:


Origonal reason it seized (suprisingly enough, everything else was perfect in the motor: