DOCWOB - KX 250 2 Stroke Tommy Searle Bike Build - Part 1

SEASON 2, EPISODE 4
The VMXdN Foxhill bike builds begin. In this episode Tommy Searles KX250 frame is back from the powdercoaters and we start to put her back together. We were talking engine cases this week, freezing, heating and what we do so the cases go back together smoothly.
We take you behind the scenes at DocWob HQ and give you an in-depth look at exactly what goes on day to day and introduce to a couple of the team and the orange workshop. Martin our engineer is working on some factory replica chain guides, and we look at what he is doing.
The plan with the TV channel is to have a mix of updates on what we're currently working on. We are working on a "how to" section. We will share techniques learnt over a lifetime of building Evo bikes. We also show you some "new products" we make and why we make them.
If there is anything you would like to see, please let me know in the comments.
Don't forget to Subscribe to the channel, so you don't miss an episode!
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[@markbarter9717]

Don't make me wait 2 weeks for the next episode 😮

[@docwobtv]

We’ve committed to doing a drop every 2 weeks for the next 12 months to see how it goes, I don’t find it comes naturally to be in front of the camera but I hope it gets easier!

[@punyamami6245]

@@docwobtv vhbgvhb vhb vhbgvhbgv

[@bobbyblenio4571]

Straight to the Point…No BS or Cheesy Comments…Absolutely PERFECT Builds,my Favorite MX Bike Build Channel 🦾

[@docwobtv]

This means a lot!!!

[@Sn0w1981]

So satisfying seeing it going together like it should. No banging and swearing and throwing tools. Top notch video, matches the work!

[@docwobtv]

Cheers bud and sharing is caring!

[@davidstevenson7925]

That’s a subscription right there! Easy, and to the point. Finally

[@docwobtv]

Thank you!!

[@onlygazza]

I used to race mx with Tony and his brother in the amca in the same club years ago and it’s great to see him doing so well, brill vid 👍 and yes my 21kxf 250 has the same headset bearings gone, rusted right up !

[@docwobtv]

I will give him a shout for you and they are so bad for it!

[@kevinf2231]

Great video. Been buying doc wob parts for many years now, from titanium bolts, exhaust hangers to peg mounts and there stuff is beautiful.

[@docwobtv]

Glad I could help

[@Evo836]

The Doc and the team doing it!

[@docwobtv]

Thanks bud!!

[@gcostanza2115]

Very interesting to see the skill and effort that goes into reviving these classic bikes. I’m looking forward to seeing the inspiration behind this build and looking forward to seeing Tommy test it!

[@docwobtv]

You and me both!

[@davidcoulson4717]

Love this Doc… attention to detail is incredible ❤

[@docwobtv]

Glad you like it!

[@moto3463]

Very hard to make a dirtbike look clean and run well love the custom manufactured parts I love development of parts you could look into making pipes ect millions of parts that the average weekend warrior like myself could buy. Love it.

[@docwobtv]

Couldn't agree more!

[@bxxxx6840]

What a quality channel.

[@docwobtv]

Thanks my man!

[@rosco162]

Proper job! That's how it should be done👌

[@docwobtv]

Thank you sir!

[@BennyBen9]

Brilliant. Love all the detail with out the faff. Great video

[@docwobtv]

Many thanks!

[@herbertklausen7912]

great episode

[@docwobtv]

Thanks bud!

[@earl6969]

It's the little things that matter to the trained eye. Graphics and crazy seat colors with ritzy rims pulls the eyes for attention....but I like the trick stuff you actually have to seek out. That's why your bikes intrigue me...that and Tommy will throw a leg over it and spank it properly. Props

[@docwobtv]

Thanks for noticing!

[@tmkickinnstickin4503]

Great video, 270 rear rotor is huge... My 20 450 has a 250 I think and all that thing wants to do is lock up and make cornering smooth tough...

[@docwobtv]

We make a 240 rear with billet carrier which is oversize for bikes from 89 thru 02, ( we do make a billet carrier for the 03/08 kx but that came stock with the 240 disc) the front we make is a 270 floating disc with billet carrier for fitment from 89 thru 05

[@tmkickinnstickin4503]

@@docwobtv he's way better rider than 99% of us... Those bikes you build are very nice if I could afford it I'd love a done up 2 stroke with some valved suspension for my size and skill. I bought this 450 not knowing these things just aren't that ridable but I find myself wanting more power on the 250f... Wish they made a 350 like KTM that Kx or the YZ would be a awesome 350

[@jasonrathbone2937]

So epic !!!!!!

[@docwobtv]

More to come yet!

[@07Leebo]

Brilliant footage from Doc and his team, the level of details is insane... great watch!

[@docwobtv]

Thank you sir!

[@paulwilliams8588]

Work of art❤

[@docwobtv]

Thank you

[@deanharriss2029]

Another wicked video rob. Keep um coming.

[@docwobtv]

Cheers bud!!

[@leonjones7404]

Loving these videos wob, brilliant camera shots too mate!

[@docwobtv]

Thanks a ton!

[@krp1787]

Great to see fantastic work 👍

[@docwobtv]

Thank you! Cheers!

[@docwobtv]

Thank you! Cheers!

[@jackbeddoes4416]

Great this Is. I am from Worcester too. Love the channel

[@docwobtv]

Awesome! Thank you!

[@jackbeddoes4416]

@@docwobtv I wanna come to your place and look at the bikes soon if poss? I like the tc 250 you got

[@mikeking7388]

Love this channel man top notch stuff!

[@docwobtv]

Cheers chap

[@simpy112]

Brilliant video guys. Cant wait to get back to foxhills in August.😊

[@docwobtv]

Can’t wait see you

[@luismelendez935]

Great video and great details! I'm building a kx 250'98 and I'm looking for the clutch actuators lever

[@barryjackson2197]

Brilliant video... well explained and tips to..love it..you guys know your stuff 👌👌

[@docwobtv]

Glad you enjoyed it

[@paulpaul5606]

Great videos very interesting keep them coming Doc🇬🇧

[@docwobtv]

Thanks, will do!

[@tessbushell5489]

Love seeing some good engineering 👌🏻

[@docwobtv]

Thankd

[@bayselec]

Great job trick piece of kit, carnt wait to see Tommy spinning some laps on it. 🚀🚀😎😎

[@docwobtv]

Me neither

[@keithfenwick5502]

Awesome great job as one would expect 👍🍀🙏

[@docwobtv]

Glad you enjoyed it

[@TrialTube]

Mega video we love it!

[@docwobtv]

Thanks guys!!

[@paulhatch9020]

Great vids glad yr doing these. Ref that kxf head tube water issue,I have one and didn’t no about this if it’s possible to shed some more light on that please 🤙🏻

[@docwobtv]

The frame just fills up and rots the bearings

[@paulhatch9020]

@@docwobtv ok and do u no or point me in the direction of a fix?

[@docwobtv]

We discovered that every 21 & 22 kxf we get thru the doors have knackered steering bearings, a bit odd so we did some research and the down tube is open into the steering head tube on the frame, I’m guessing the seals on the bearings are not great aliasing muddy water to fill the down tube then it splashed up basting the bearings making them rust, I assume you need to remove the motor and drill a small drain hole in the bottom of the down tube but I’ll ask about and find out what the factory teams are doing to sort the problem

[@paulhatch9020]

@@docwobtv that would be brilliant if you could and give me an update would be much appreciated. Really glad you have brought this to mine and I’m sure many others attention 👍🏻

[@TS50ER]

That cylinder head stud tool is the dog's.

[@docwobtv]

Yea Chad watts ( RC’s mechanic at the time)got Pro Circuit to make them for him so then we all wanted a set! I don’t think they’ve ever been available to the public to buy- should we make them??

[@TS50ER]

@@docwobtv .Obviously not my decision to make, but here's my 25 pence worth: It's is not a high-frequency tool, but sure beats messing round with two nuts. I guess it wouldn't be expensive to produce; and it isn't a big-ticket item, so it they don't sell, you wouldn't be out by a lot.

[@peteodonnell4494]

doc wob top job 🙂

[@docwobtv]

Cheers

[@bikevault2302]

this is going to be an awesome channel.

[@docwobtv]

Thank you

[@KX_Generation]

Nice job for a nice bike ! I l like this ! 💚

[@docwobtv]

Why thank you!

[@JacksonD489]

Proper job...

[@docwobtv]

We don’t mess about bud!

[@davethomas7881]

i do hope that tom appreciates all the work that is going into this kwacker did you say that this is just his test bike docwob?

[@docwobtv]

It is indeed just the test version!

[@EarthSurferUSA]

Don't bother freezing bearings, they don't shrink very much. I found that a cold bearing sucks the heat out of the cases, and if you have any problems getting the bearing straight, the cold bearing shrinks the cases on it a bit crooked. I just press them in now, with a bit of lubrication. Got tired of burning my fingers. :)

[@docwobtv]

I was thaught this method by factory Suzuki.

[@littemisscarrage2909]

nice gaskets

[@docwobtv]

Cheers

[@rybikes6630]

Great video. Will the disc brakes and billet attachment fit a 03 kx125?

[@docwobtv]

We have the oversize floating 270 with carrier in stock and the rear carrier will be in stock within a couple of weeks- though the rear is 240 from 03 onwards

[@roblastname9133]

Love seeing your builds,great stuff. Something a bit special on tommys build? Tommys a bit special 😂

[@docwobtv]

This one is just the test bike, the next one is going to be insane

[@roblastname9133]

Can't wait for it fella👍

[@chrispeterson73]

I'm just curious to know if there's a kit available to convert a rear drum brake over to disc on an 1984 kdx200? Love the way this bike is shaping up, BTW! Thank you in advance for any and all info. 💯🔥👍

[@docwobtv]

Not as far as I know, sorry

[@rtrshop9222]

Hi do you make the oversize front disc and rear brake carrier for the 07 kx125?

[@docwobtv]

The rear carrier we make for the 07 but it comes stock with a 240 disc so it’s not an oversize mod on that one- the front carrier will fit the forks to take our 270 front disc but our disc only fits the up to 06 front hub I’m afraid

[@EarthSurferUSA]

What year KX is that? I had a 97. Maybe a bit heavy, but I got fast on that bike.

[@docwobtv]

These are 2001

[@mikebrown41182]

I am curious, what cylinder studs are those Doc?

[@docwobtv]

They’re re plated stock, we run titanium nuts so never ever run ti nuts on ti bolts

[@Gerald-en2ih]

Same Problem with the steering stem bearings on my 21 KX450. I am very picking on bike maintance but cant find any solution for this problem. Do you have any aftermarket parts that will solve this problem?

[@docwobtv]

Not yet we just figured it out so I’ll ask what the factory teams are doing to fix it

[@Gerald-en2ih]

​@@docwobtv Ok thanks for the fast response please let us know when you find any solution for it. Thanks from Austria

[@Peanutdenver]

I'd love to give my 2-smoke this kinda TLC, but all my coin goes into my 450 race bikes. Great vid btw, these are just moto-porn at the highest level.

[@docwobtv]

You need to give the 2-stroke some love!

[@jordanloeffler4879]

Hate to say it but the powder coated should be masking any threads

[@docwobtv]

This is the way we have found best to do it after 35 years building thousands of bikes after powdercoat, we find if the threads are plugged the powdercoat simply piles up like a snow drift so we find it a better job to sand it off and chase the threads, if you prefer to do it another way then I’m happy for you

[@jordanloeffler4879]

@@docwobtv that is very true. That didn’t even cross my mind. I take back my statement lol. Love the content

[@roostfezza7563]

Can you purchase any of these special made parts?

[@docwobtv]

You can indeed my man, just give us a shout! (Website)

[@pauldelahunty2538]

I offered doc a original sr250 crankshaft few months back and he refused 😅

[@docwobtv]

Yea I remember, the problem with getting one part is like one piece of the puzzle, without the matching piston, cylinder, powervalve, Reed block, flywheel, electrics & pipe it’s unlikely to do very much on its own, if we keep it all stock with pro circuit cylinder & head mods then the matching pipe we stand a fighting chance of getting it to run

[@pauldelahunty2538]

@@docwobtv hey its the same as a standard crank tbh just had the Sr code on it I'll have my build at vmxdn this year mabey pop over and get a few tips 🤣🤣

[@mattmanning9267]

Have you ever wanted to build a bike of your own design?

[@docwobtv]

Always!

[@mattmanning9267]

I take it money has prevented it; but a video describing what design you would like to build would be fascinating.

[@kevinwestwood6668]

Should Tommy Searle be racing the vets des nation's, he's a current professional rider, and not exactly a veteran, racing the British championship, perhaps tomac, will come for the American's.🤔🤔

[@docwobtv]

Yes Tommy is of legal age to be classed as a vet rider in the rules for the VMXdN foxhill which is the event we’re building this bike for

[@Coopdegras]

"We only use an impactor to take stuff apart, we tighten everything by hand" you don't know how much little things like that satisfy an ex ocd mechanic, kids these days building bikes on here with impactors makes me cringe.

[@EarthSurferUSA]

Me too. Just lazy. I take apart and put together a lot of little 2-stroke engines. I use a little pneumatic driver to save time for assembly, but finish tighten them by hand to the point of tennis elbow, (lots of repetition). I have to sell the stuff right.

[@docwobtv]

By hand all the way in ( just incase)

[@Coopdegras]

@@docwobtv are we still talking about using impact drivers on bikes here wob? 🤣