1999 Kawasaki KX250 Build

Build List

Description: The Flow One Resto Mod '99 KX250 2-stroke. A full frame off restoration complete with all the knick knacks and paddy whacks that any rider would appreciate. The bike is supplied with the original Certificate of Origin.

Engine & Performance:

  • Phathead Racing Cylinder Head (20.2cc)
  • Rekluse TorqDrive Clutch System
  • Spec Bolt Nickel Wurkz Engine Fasteners
  • Cylinder Re-plated by PowerSeal USA
  • Crankshaft Rebuilt by X-Pro with ProX Connecting Rod
  • Hand-Polished Engine Cases
  • Polished Keihin Carburetor
  • VForce 2 Reeds
  • Pro Circuit Platinum Expansion Chamber
  • Pro Circuit R304 Shorty Silencer

Chassis, Suspension & Drivetrain:

  • Frame Powder-Coated by Legacy Designs
  • Primary Drive Chain Guide
  • Galfer Steel Braided Brake Lines
  • Mika Metals Front & Rear Sprockets
  • DID ERT3 Gold Chain
  • Maxxis Maxxcross SI Tires
  • Tusk Black Rims
  • Polished, Rebuilt, and Clear Coated Forks, Shock Absorber, Linkage, and Swingarm (Cerakote MC5100)
  • Polished Shifter, Brake Pedal & Kicker
  • Tungsten Cerakoted Wheel Hubs, Triple Clamps, Engine Covers & Footpegs, and Brake Calipers
  • Graphite Black Cerakoted Clutch and Ignition Covers
  • Titanium Cerakoted Axles (Elite Line)

Controls:

  • Mika Metals Oversized Handlebars (RC)
  • ODI Bar Mounts
  • ODI Lock-On Grips
  • Works Connection Fork Bleeders
  • Works Connection Clutch Perch & Lever

Plastics & Aesthetics:

  • Polisport OEM-Replica Plastics
  • Action Sports Decals OEM-Replica Graphics

The Story

A true handcrafted masterpiece. This bike was completely stripped to the bare frame — every piece disassembled, inspected, and reborn. What started as a tired, weathered 1999 Kawasaki KX250 has been transformed into a work of art, restored from the ground up inside a humble home garage.

Every component was restored by hand. The frame, engine, carburetor, and hardware were refinished and rebuilt with precision. The wheel hubs were Cerakoted, fitted with new bearings, and laced into a fresh set of Tusk rims and spokes. The factory swingarm was stripped, polished, and clear-coated with Cerakote MC5100 to preserve its brushed finish. The exhaust was carefully polished using soft PRYME wheels, keeping its original nickel plating intact.

All Cerakote work was done with a $40 Harbor Freight handheld sandblaster and a $50 Walmart toaster oven. All the polishing was completed using a $50 Amazon bench grinder, a $20 Walmart rotary tool, and PRYME MX cleaning wheels. The engine cases were hand-polished — proof that craftsmanship matters more than fancy tools.

Every detail reflects the same level of care you’d expect in a factory race shop. But this KX250 isn’t just a rebuild — it’s a showcase of persistence, precision, and a deep respect for the process of bringing something forgotten back to life.

Every bolt, every polish, every late night led to this moment — Flow One’s 1999 KX250: a garage-built icon, restored by hand, and built with heart.

Build Episodes

Before

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After

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