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Token Short Guy
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321 Posts
Discussion Starter · #1 ·
Well I sold my FZ700 Fighter project and picked up this new toy about 2 months ago, Its a 1983 KZ250 (CSR 250) Belt Drive. I wanted to build a little small cc bobber for around town. This thing factory weighed 300 lbs. With everything I've cut off so far Im sure its alot less, And even with only 19 hp it moves pretty good. Ive been working for about 2 months now, So I'll try to catch up this forum in a few posts...



I didnt snatch much for pics as I got it, But started taking pics as I started tearing it apart...







Started removing stuff...






 

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Token Short Guy
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321 Posts
Discussion Starter · #2 ·
Uni Pod Filter


Removing more un-needed stuff










Removing Paint From Forks...


Yes It has solid struts... Keeping with the ultra low budget and the fact the swing arm has to stay removable for the belt drive, I made some solid struts








 

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Token Short Guy
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321 Posts
Discussion Starter · #3 ·
Now here comes the part where I'll get more mixed reviews, I know alot of people hate the solid struts and I know alot of people will hate my tank, But here it is. The tank is sticker bombed. Here it is on the bike before clear coat










Got working turn singals. Now I found out in Va you have to have front and rear, or none at all, I dont want fronts...



All wiring tucked under tank now






Time to fix the starter problem






Was told the starter clutch was bad, After getting it all apart, starter clutch if fine, sprocket that the starter clutch grips on is broken in 2, The center broke out completely, And most places says its obsolete, So this weekend Im welding it .Oh yeah total cost so far is at $98!
 

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Token Short Guy
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321 Posts
Discussion Starter · #4 ·
Some pics of this 2 weeks ago tear down to fix what I was told was just a starter clutch. A shop looked at the bike and told him it was a starter clutch, Maybe the inch of play in the sprocket wasnt noticed lol



Looks normal right?


Not so much




Everything else looks really good...


After waiting almost 3 weeks for someone that said they could get the sprocket...Im just going to attempt to weld it! :doh:
 

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Token Short Guy
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321 Posts
Discussion Starter · #5 ·
Little more work, took the bars and and started cleaning all that up, Previous owner rattle canned everything flat black, but didnt prep shit!

Bars before, flaking paint...


I can ride my bike, with no handlebars


Bars sanded and primed


Black Paint


Riser caps, With Matte Clear on them


Matte Clear on bars...
 

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Token Short Guy
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321 Posts
Discussion Starter · #6 ·
In the spirit of being a cheap ass, I recycled some metal from work, We're scrapping a deep fryer from a Chick-Fil-A, And the drain panel has a perfect 90 degree panel in 14 ga stainless. So of course I asked if I could have it before they sent it off.





To this


To this


And bars going back on
 

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Token Short Guy
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321 Posts
Discussion Starter · #7 ·
And thats where Im at now, I broke a fitting on the carb and had a big conversation about fixing that on the other forum, no need to bore you with those pictures. Drilling and tapping it and a barb fitting, no biggy. More updates to come!
 

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The Soft Serve Enigma
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16,719 Posts
That's awesome, I love it!
 

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Token Short Guy
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321 Posts
Discussion Starter · #10 ·
Just snatched a red metal flake La Rosa Solo seat off ebay with Scissor springs and mount for $62 last weekend, Should be here on Wednesday. As soon as I get a lil more money I need to find a H4 headlight housing so I can run some 3000k (Yellow) HIDs and a bar end mirror for it
 

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Newbie
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387 Posts
cool lil build man! we just took our KZ200 off the lift last night! dig the sticker bomb paint job! saw that in a chop mag a while back... looks sick. when your doing your final tune be sure you points are perfect and the gap on the plug... if it is off the bike will run really fatty. cool project man. here is the lil one we built to run back and forth between my house and my brothers... powder coated the crap out of it, some airbrush work on the tank... and knobby tires so we can still ride it in the snow! hahaha still workiing on the amo case saddle bag

 

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Custom bikeporn addict.
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1,241 Posts
Love it so far. Actually thought you were going white with the bars at first. Then saw the black. White might have been good to go with the sticker bomb, but then you'd have to do the frame too.

Stickerbomb looks cool. Diggin the struts too though maybe you can do something to them to make them unique, and I don't me a tribal pattern cut out lol

Also, that flywheel looks suspiciously like the one on my ex500. If it is similar it would mean that the epoxy holding the magnets on will flake apart and let the magnets loose. So if you hear a ticking sound from the cover then it may be bad news. Also I believe that the ex500s also have issues with the starter clutches breaking.

Overall, looking great!

Bob
 

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That guy
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4,468 Posts
if its so similar to an EX500 motor wise, why not just do the ninja swap!?

Before my cousin sold his little 250 bobbed rebel I was trying to get him to swap in a 500 ninja motor, he never did go for it. Love the little light weight bikes, just give it more oomph.
 

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Custom bikeporn addict.
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1,241 Posts
if its so similar to an EX500 motor wise, why not just do the ninja swap!?

Before my cousin sold his little 250 bobbed rebel I was trying to get him to swap in a 500 ninja motor, he never did go for it. Love the little light weight bikes, just give it more oomph.
Belt vrs chain? dunno if they have a conversion for it?

Motor may have similar parts but different overall size and layout too.

Bob
 

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Token Short Guy
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321 Posts
Discussion Starter · #16 ·
Its not really Similar as far as most parts go, Plus this thing runs great and I like the fact that its a Single Cylinder. This thing tops out at almost 80 with me on it, Thats all I need. And I enjoy my mpg :)

Its actually pretty common for people for convert these to chain, But I see no need to swap motors, These little singles are pretty much 1 cylinder lopped of a 1000 motor and pretty damn bullet proof. Other then the starter problem this inside is spotless
 

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Winter's comin... :(
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4,869 Posts
I have one of these sitting outside my fathers house... Chain drive tho. Its in several pieces right now, and I'm not sure of I'll do anything with it.

Nice build so far. If you need parts off mine, lmk.
 
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Token Short Guy
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321 Posts
Discussion Starter · #18 ·
I have one of these sitting outside my fathers house... Chain drive tho. Its in several pieces right now, and I'm not sure of I'll do anything with it.

Nice build so far. If you need parts off mine, lmk.
What year is it? I can cross some part numbers and def migh need some stuff
 

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Token Short Guy
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321 Posts
Discussion Starter · #20 ·
If I could find a definite answer on if I could swap covers etc and get a kick start from a KZ200 to work I would just do that and not worry about this obsolete starter sprocket
 
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