Well I was given a 93' 250EX from a friend for free. It had been dumped 3 times, and it shows. I have removed all the fairings, and made a list of needed parts. So far I have had good luck on ebay with a lower fairing for $55. I still need to locate a upper fairing, seat, driver left side foot peg/shifter linkage mount, and a windshield. The bike was painted that color changing purple and green paint, with purple pegs, and winshield. All the purple parts have been removed also, I don't dig purple. I have stripped the paint off the tank, and rear grab bar. I plan on sanding all the plastic pieces, and priming them soon. The bike is mechanicly sound, and most of the repair is cosmetic. I don't have any before pictures, but I will try to snag some of the bare bike, and the pile of parts I have so far. I will take pictures of my progress and post them up for you guys. This is my first time working on a bike, and will be the first bike I ride. Wish me luck!

 

Sounds like me a couple of months ago.
https://www.kawasakiforums.com/m_87542/tm.htm
Well i did get it running after a couple of carb cleanings. I ended up taking the carb apart and cleaning it with carb cleaner and compressed air. I did have some fairing damage. The previous owner patched them back together, however there was a lot of small fiberglass work that needed to be done. I have had it running for the past month and a half. In that time I have put mirrors on it and new turn signals on the front. Both were bought off ebay from the same company. I forgot the name but you will see them on ebay when shopping. Seeing as I am still new I must say this is the funniest toy I have ever had. I love riding it and being in Tampa I get to ride ita lot. It is crazy to think, but i have more money in the safety gear than I do in the bike itself. Here some more recent pics of her. The new mirrors and turn signals are tight looking to me.




Good luck and get sticky screwing with that fiberglass.

 

your bike looks nice, mine was in shambles...fairing pieces hanging off. haha

I got the tank stripped and found one little spot of bondo. I'll have it sanded and primed by the weekend.



I used a can of spray on aircraft stripper and a 1" metal scrapper.
I also did the grab bar.

Does anyone know of a fairing friendly stripper?

 

That took some elbow grease, i bet. What color are you going to paint it? Friends have asked me if I was going to paint mine. If you get up on it you can see a lot of blemishes. I told them i wasn't, because since i have fixed it I can't stay off of it. There is only one other thing i like riding more than that bike.[sm=smiley2.gif]

 

I'm going to use a 99' Chrysler color, I forget the name but it's a redish copper color. Should be nice.

 

Can't wait to see the pics of her

 

You will have to wet sand (as in a tub of water) all the paint and clear coat off. Then prime and paint. Be careful not to go down to the plastic or you may have issues with the primer sticking.

There are fairings at airtech if you cant/dont want tosalvage yours, although with the proper stuff anythings possible.

I also found some cool non-oem design fairings for the 250, they would need some adjusting which it sounds like your up to, unfortunately Ive lost the link but Ive seen them a few times so a good search may find them. I havent seen or heard of anyone actually using them though, just putting it out there.

 

I'm famlier with wet sanding, and I would think using an adhesion promotor would help if I took it down to the plastic.

I did quite a bit of reading on theforum and I think I found the site your talking about, I think they sold the rear seat delete also?

 

I sanded the rest of the paint that was left with some 180grit. There were some rust spots and a dent that was filled with bondo. I'll hit it with some new filler tomorrow.

Here is the bare frame, sorry the pic is so bad, I had no light.


and the tank after sanding.

 

Airtech does sell a seat cowl too. Their plastics are close to oem design. I still cant find the other site.

I wont be any help when it comes to paint/primer adhesion, I wish I had more wisdom myself, I can only go by the troubles of others. It sounds like you may have access to some decent paint Im sure you will get better results than the "over the parts counter" stuff.

I have researched it some, I took the paint off the front of my tank and need to paint it. Hopefully there will be a break in between freezing and 100% humidity this spring.