How-To: Kawasaki KX125/KX250 Top & Bottom Engine Rebuild 1994-2007
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- เผยแพร่เมื่อ 30 มี.ค. 2016
- www.howtomotorcyclerepair.com...
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Tools and parts used in this video:
Motion Pro 08-0134 Torque Wrench Adapter 12/14mm
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Motion Pro 08-0008 Clutch Holding Tool
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Motion Pro 08-0427 4.9" Gear Jammer Tool
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Motion Pro 08-0026 Flywheel Puller M27X1.0 L.H External Thread
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Tusk Crankcase Splitter
amzn.to/1QKDCrG
Tusk Crank Puller/Installer Tool
amzn.to/1QKDIzl
Tusk Crank Puller/Installer Tool C-clip Adaptor KAWASAKI KX250 KX65
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BOA BO13010 Constrictor Aluminum Strap Wrench
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Lisle 56750 Seal Puller
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Impact driver
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Vessel P3 JIS Screwdriver
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Vessel P2 JIS Screwdriver
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IR Temp Gun
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Assembly Lube
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Moly Lube
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Three Bond Sealant
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Hot Rods CBK0055 Bottom End Kit
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Wiseco Piston Kit 617M06640
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Pro X Rod Kit 3.4309
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Hot Rods 4017 Crankshaft
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Thse videos cover the KX125 KX250 models. Years 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 are covered. Every step is covered in this video tutorial.
Covers KIPS powervalve in detail
A new Wiseco piston was installed. Cylinder, piston, and clearances are measured.
Piston ring end gap was measured
Water pump seals and bearing
Splitting the cases
Disassembling/assembling the transmission, shift forks, and shift drum
Removing/installing the crankshaft
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Buy full video HERE - howtomotorcyclerepair.com/kx250-engine-rebuild
Blog post with more info - howtomotorcyclerepair.com/kxenginerebuild/
REMEMBER this video is FOREVER so every ounce of energy you put I'd forever APPRECIATED by all the curious top to bottom.
I'm 43 in 2022 been into dirt bikes 2 stroke since in 12 untill 22 but never got deep into it cuz of cars and girl's but now it's my time and I was LOOKing for you to show me.
When I get back in I will support you my friend
Just got a running 95 kx 250 this will be very useful in the future thanks man
Man awesome videos finally somebody that covers everything!And not just 15 mins on how to do the shit right!Great video buddy!💯👍
I bought your video, thanks so much. I have 2 bikes 97 kx125 & kx250 so this video will help out tremendously.
Im going to buy it soon and watch a millllllion times and buy a kx ore honda when i finish my year in the norwegian airforce :D Thanks for the amaaazzzing videos
+John Steinar Hansen Thanks for the compliments!
Thanks! I’m about to do a top end to my KX 250 also a 2001.
Man this channel is gold🤙
Thanks for showing me everything but what I need to know.
Hey no problem man. Good luck with the rebuild.
I like youre Vids! Everything i know about the Kx 250 i now from you ....its so nice you share youre knowledge with us 😉 thanxxx I own a 2002 and i go to rebuild it ,the next months .. greetings from Germany
Thanks for the compliments!
I love these bikes, i’m currently own a 1980 Yamaha DT 250 MX and ride almost every day, but my true love was my Yamaha IT 175 that I owned when I was 17 ( 52 now ) oh how I wish I had it now lol 👌👌👌
Thank you for the information bro
I have the same milwaukee impact I love that little sucker, it's powerful too!
Yeah I know! I just ordered a 3/8 version. The 1/4" impact takes apart the entire bike!
Thanks for taking the time to do this!
Kinda vague/ambiguous on certain parts and the metals used
@@rw499 Everything is covered in the full 6hr video.
@@HTMR do you have diagrams ? I am interested, but don't want to be let down
@@rw499 Diagrams for what? You can download the service manual for free on my site. Exploded diagrams can be found on RM atv or any OEM site.
You should really do a 2 stroke yz250!! I'd buy that video. Your pricing is really awesome as well. If I was in Chicago I'd be on the way to drop my engine off at your place
Awesome video!
Thanks!
Question- kx250 - after hitting neutral in high rpm between shifts, and then jamming it into 2nd gear, my bike shut off and won't go into neutral or 1st. The Bike Runs Because I Was Able To Get Out The Trails In 2nd/3rd gear. Do You Think it can be simple as a shift fork popping out/loose or the gear or shift drum won't slide ? Thanks In Advance, I Have To Buy The Case Splitter And Fly Wheel Puller For This Job. 👍
Hey I need the right middle side engine case for my 2001 kx250 do you what year compatible
thanks for this! I'm assuming I can follow all of this for my 1990 KX 250? I just picked up this bike so learning what I need to do to make it brapp
Yes sir! Your 90 will be a bit different, however and the tips and procedures in this video will help.
I like to now if the crank of a 2005 kx 2 stroke fits the 2006 I'm in Australia doing a rebuild on my kx and can't find rebuild kits for it
Ok I'm subscribed and I have a 98 kx250 all I need to know is the flywheel and stator cover torque setting I already know the flywheel nut it doesn't say anything in my manual it just says tighten accordingly 😮 I don't have time to watch the video also the power valve covers torque spec isn't in my manual either can you please give me the specs thanks in advance 👍I'm installing the works nickel dress up kit if I don't hear from you I'm just going to torque them down to 16 to 18 ft lbs lol
Purchased Thanks!!
+Hillermi10 I see that. Thanks so much!!! Enjoy!
Great video. I have a kawasaki 1990 KX125 and it needs a new water pump but I cant find one just need help looking for one
Not available from the OEM?
Hey brother I just bought your full length kx250 video. How can I access this video/purchase
Good
Cool vids.. how do u torque the cylinder head nuts? The ones that the sockets don't fit on because of the socket thickness? My socket only fits on one so I've just done the other 3 by feel from the first one..
My regular chrome socket worked no problem.
any kits for a 1998 or 1994 not sure which year the seller said 98 but vin indicated it’s a 94 I can’t find a bottom end for either year and don’t know what to do as I spent a lot of money the bike is mint just needs rebuild
Thanks Matt! I'm getting ready to pick my 2003 Kx250 in another state. Gotta do some work, its been sitting. Rear rim is bent, needs fork seals, spark plug boot, carb definitely needs a cleaning and new jets, air filter definitely and probably a new top end. I wanna take the bike apart in order to fit in the trunk of my car, any suggestions?
How you make out?
@@bunnyman6321 bike is sitting in garage now. I drained the shit gas and rejetted the carb and new air filter. Also new spark plug and spark plug boot. Started 2nd kick. Runs great! Breaks a smile to my face. Just got order new rim and do front fork seals.
@@zachariahjohn4040 You gotta take it for a spin now; it's time to ride 😎
Bel video.ce lo uguale identica.ho ti fatto il motore ora quando la valvola si apre del tutto si sente un suono metallico un tintinnio.mica puoi dirmi cos'è.vedo che la conosci così alla perfezione grazie.
Why dont you have a condesor on your bike? Mine has one but dosen't connect to the wire harness.
I'm purchasing a 95 saki KX125 with bill of sale the bike is immaculate all is in order except the engine of off entirely groom the chassis of the MX. Would you greatly recommend I completely rebuilt it in wiseco parts crank bearing the while kit ?? Is it reccomendable? A good project I see it as
I would go oem for parts. Have the crank rebuilt if stock.
Thats cool man. I hope this system is working for you. I have a low hour 94 KX250 that hasn't been ridden in 15 years. I might take you up on your video. Thanks!
Hi Chris, yes the cranks seals will be suspect after sitting that long. You will have to split cases to replace them.
How you make out?
@@bunnyman6321 It runs great but I haven't "ridden it". Its a VERY low hour bike and I am trying to keep it original. With the carb cleaned and some fresh fuel it fires right up. It does need fork seals now. Sitting that long is hard on stuff.
@@chriswesney What plans you have for it other than keeping it original n servicing it?
@@bunnyman6321 My uncle bought it new when I was a kid. I lived with my aunt and uncle back then so its like a family heirloom I guess. I just like having it. I have other bikes that I can ride so my idea is just to preserve it for now.
Hello, very nice video projection. My son have a KDX125, 92 in a very bad condicion and is looking for service and user manula instructions can you help. Another great video.
I don't have a service manual for that model, however look here: www.tradebit.com/filesharing.php/search/0/kdx125
Hey mate, will a 2002 kx250 crankcase set bolt up to kx250 2001/replace a 2001 crankcase and transmission.
Basically are the 01 - 02 crankcases interchangeable?
PN are different, however that does not mean they won't work. Ask your question here: thumpertalk.com/forums/forum/76-kawasaki-2-stroke/
you are the best 😉😄
Thanks!
Have a yamaha dt100, 1977 that reams really bad when i start it or hit the throttle. Cleaned tank, new plug but did not clean the carb. The throttle cable could be the problem but not sure. Any suggestions as parts are very expensive for this bike. Need to attack the obvious problems first. My first restoration project. Your channel is Awesome! Thanks, Wayne Brown, Rochester NY.
+wayne brown Wayne, email me here and I can help you out www.howtomotorcyclerepair.com/contact/
Please tell me where to get a fuel gauge and how to install a fuel gauge on a honda shadow spirit 2006 as you know the motorcycle doesn't come with a fuel gauge
I have a question is your bottom end rebuild video specific meaning does it show which bolt goes where and where washers go and stuff. I am asking because my cousin took my motor apart and now i have to put it back together. I was wondering if your video would help me
Yes, it will help you. I also have the service manual on my site for free. It would be a good idea to print all the parts diagrams as well. With those 3 resources, you will have no problem.
I purchased your video & it's great. I was wondering if you have a supplement for a KX125 power valve as they are different. Mine happens to be an 03.
I don't sorry.
Did you figure it out?
Hey there, thanks for the videos! I have a question, I am not getting spark with my kx250. No spark at all. I've tried changing out the plug, checking grounds and connections, and ruling out that it isn't the kill switch. Where would you go from here? are you able to do a video on testing the coil and other electrical components in a kx? Thank you
Grab the service manual from my site and the electrical section should have some testing info for you. I haven't messed with mine so I can't comment on what to do: www.howtomotorcyclerepair.com/kx125-kx250-oem-service-manual-99-08/
Ok, perfect thank you. Those manuals are what I am missing!
Keep me posted on your spark issue.
Very nice job! I just got a 98 kx125 will be my first rebuild and Im about to buy your video, what is the link for it?thanks in advance
Here is the direct link: gum.co/LnZg
Hi friend, thanks for the video. I have a Kx 250 year 2002, I want to change the joints and oring. Does the video you sell show how to disassemble and assemble the kips system?
Yes.
@@HTMR can you send me the link?
@@jajaja3217 www.howtomotorcyclerepair.com/kxenginerebuild/
so I have a question. I bought the disassemble and assembly videos but I need to replace the connecting rod. how do I get the big pin out and the stuck Bering without A special tool
You will need a press. Just send it out for rebuild, should cost about 180. Sorry for the late response, I just saw this comment.
Hey matthey does the kx 1998-2007 all of them have the same piston size
I don't know sorry.
Im rebuilding a 99 kx125 fpr my shifter kart.... Cant find a wrench rabbit for this year. Is there no aftermarket crank for this year?
Do you have the stock crank? If so, why not have it rebuilt for $170?
I have a question about the cases. do you know if the right side case of a 2003 would fit a 2002 because I need a new case
I don't know. Look up the PN for both years and see if they are the same.
TOP! video
nice kx
Thanks.
Was that gasket sealer that you applied on the case?
+TWiNS MOTO LiFE It was hondabond. I believe the company Three Bond makes all the hondabond, yamabond, etc..
You basically want a grey semi drying sealant. Here is a link: amzn.to/1qmigFk
I have to rebuild my 91 kx125. how much different is a 1991 compared to 94 on up as in this video?
Bill, I replied to you email.
MatthewMCRepair I also have a 91 kx250 how much different is it from a 94?
It will be different. Not sure how much. However, tools, tips, procedures are the same. If you end up buying and it does not pertain to your model, ask for a refund.
You are doing a great work. I have a KX125 2000, last time i rebuilt my engine i included new top end, piston, new cylinder and new disc plates. The bike is working fine, i have tried several different jettings, BUT i cannot obtain the power i had when i bought the bike 7 or 8 years ago. It seems i can't find the reason of power loss...What could be the most possible reason? Any idea would be appreciated
Check compression. Pull reeds and inspect. Pull pipe and inspect piston/cylinder wall. Remove power valve cover and rev it up and make sure it is moving.
Thanks Matthew, i 'll open it up again for inspection and see what i can find; i am sharing your channel to our blog btw
Cool. Have a link to your blog? I'd love to check it out.
yup, dirt-bike.gr Sadly it's in greek only
Thanks....good thing for google translate :)
Hello so my 2001 kx 250 when I got it it was locked up I took the top end off and got some of the metal out and everything then it came unlocked so would I need just a top end or bottom too?
The bottom end was locked up due to metal?
@@HTMR yes parts of the piston was down in the bottom but I dug it out so now it’s not locked up
I have 2000 Suzuki RM250. Do you have any videos on Suzuki two stroke bikes. Looking for a full rebuild video.
No, I'm sorry I don't. I do offer rebuilding + video service if you are interested in that.
I have a 1998 125 I'm going thru...everything. And I like the 1998 powervalve! My water pump failed and leaked water into trans side.....I didn't know and had to replace the trans ($110, nice one) PV gov' ($11!) all the bearings were going to be replaced anyhow...the crank gear ($10), .....All is good now....coming together as I type
So that video you did would it be ok for a kdx250 1991 model at all??
Yes, however power valve and clutch setup are a bit different. However several KDX owners have bought it and said it was very helpful.
Hey Matthew, I have a 1990 KX125 that I got from a buddy and I am wondering if you know if I can swap/exchange parts from that engine with parts from newer kx125s? The reason I am asking is I would like to rebuild the engine and most of the rest of the bike to learn how everything works and get it running again. But, I have realized that a bike that old makes it hard to rebuild due to lack of part sourcing. So I was thinking maybe the other 1990s kx125 engines have a similar architecture and I could possibly swap out old broken parts for newer oem parts. Let me know what you think and thank you so much for making this video series, it is a serious life saver!
I'm not to familiar with part interchangeability, sorry. Try the KX250 FB groups and thumpertalk forum.
The bottom kit in The description does that fit an 02 kx125
Not sure, visit MFG site and see year & model in application list.
Hi I've got a 96 kx 125 what's the difference in the gearbox is all the parts the same from 94 to 98. Or do u know what years are the same. Many thanks
Not sure off the top of my head. I have all the service manuals on my site, they should have the info you are looking for.
05 was last model produced in US
I have an 85 Kx 250 do u know where I can download a service manual? thanks so much.
I don't have any free ones, here it is for $10: www.tradebit.com/filedetail.php/278873598-kawasaki-kx125-kx250-1982-1991-service-repair-manual
Does it matter which way you put the shift drum in as long as it’s not upside down and the forks line up with the grooves? Like does it have to be rotated at a certain spot before connecting the forks? I would think that the only way you would mess it up is if the forks didn’t line up in the groove
The shift drum can only go in one way. Forks need to go in correct grooves. Rotational orientation does not matter at this stage in assembly.
Does anyone know if theres a silicone center case gasket or is there a paper one, my yz had a silicone one and I cant find paper ones anywhere
What year and model YZ? Do you have the service manual? Did you look in the OEM parts finder?
hello. i just bought a kx250 1998 and the kick start only engages some times, other times it just goes up and down as if there is nothing inside.. i have seen a few videos on it and need to split the engine, i dont feel comfortable with taking the radiator off and getting everything taken apart. is there any way i can get to the kickstarter without taking everything off.. i mean just taking the engine case off? thanks in advance
tom giles
You only need to take the RH cover off to access the kickstarter.
Hello I was wondering how I can email you to ask you a few questions before I buy your video..
howtomotorcyclerepair.com/contact/
I have a 1995 kx125 i cant find a 1995 rebuild kit, what other rebuild kits would fit ?
Go with OEM parts: th-cam.com/video/eqe59cINk7A/w-d-xo.html
Hi matty I bought the how to rebuild bottom end on kx 125 /250 video and now I can't find where it is to play it. I've downloaded the gum road app and that's just more confusing can u help please. Many thanks
Please email me. I will need your email address so I can help you out.
Does this rebuild video cover the 220 kdx model?
Yes people have bought the video for that purpose. Clutch and powervalve setup is different though. If you buy and feel it does not help, ask for a refund.
whats it mean when my bike high revs 1st start up w choke on? thanks
Mine did the same, it is normal. I just toggle the choke on/off to calm it down.
I have a 96 125 it’s sucking in transmission fluid and burning it if it’s a crank seal can I change it without splitting the cases?
No, kawasaki design traps the seal in. No choice but to split cases. This video will help you out.
I know normally it’s the crank seal when it’s trying to rev up on its own but could anything else any other seal cause clutch fluid to get inside?? I’m just really trying to not split the motor I know I’m dreaming at this point
@@willcrosbie8806 Dude, it is an old bike and they simply need to be rebuild every now and then.
Hey Matt, thank you so much for posting this video. I'm currently looking to buy a 1999 kx125, the guy is asking $500 for it is blown up. Should i invest in this bike? Thank you
Blown up your are probably fine, meaning the bike turns over but has low compression. Seized up will be a bigger challenge and may require rebore.
Will this subscription of the video help with a rebuild on a 1999 Kawasaki KX80?
Yes, but please understand there will be differences. If it doesn't help you, just ask for a refund.
Do you still have the video available,and is this a step by step assembly of a completely torn down bottom end,had mine apart for a couple months now I'm starting think I might be forgetting a few things,and how much$ thanks
Yes and yes: www.howtomotorcyclerepair.com/kxenginerebuild/
Is the pistol and rod supposed to move freely when you install the water pump and the top is off
Yes.
Hey man.
I just picked up my new project bike, a 2001 kx 125. I already did top ends in the past and i have decent knowledge of tools and stuff. Do you think that watching your video i'll be able to put together the whole engine?
Also, is the video downlodable once purchased? I'd like to be able to see it without internet.
Waiting for your answer. If you want, you can give me your email so i can write you there.
Video is step by step, everything covered. Video is streaming only and you will need internet or data to view.
Hello! I am currently trying to restore my 97 Kx 125. However from the looks of it my motor does not match the year when the frame was made. This is the serial number KX125KE015985 on the motor. What is the number on your bike? If you do not mind me asking. Do you know if parts from 96 or 98 models work with this motor possibly? Anything helps. Thank you for your time!
I don't know much about the serial number and year interchangeability. I would join the kx250 riders fb group and ask there. Or on forums.
MatthewMCRepair Ok. Thank you very much!
go on bike bandit .com you can use them to see if parts interchange or are the same from year to year.
whats your fulltimejob ? are you a Bikemechanik ? I just wonder ,... very well explained
Mechanical Engineer
Understand length of vids, but how many hours labor to do the rebuild would you calculate?
For a first timer.....8 hours give or take.
Im rebuilding kx125, is it better to put piston with 2 or 1 piston ring
1 ring is less friction for "racing". 2 rings for more life/reliability.
@@HTMR Yeah, thats what i was thinking too. Thank you
Hey man I’m buying the full video today. Any way I can email you what I have going on?
Absolutely.
I brought your videos couple years ago. How do I get access to it again?
Go to my website and shoot me an email.
About how long did it take you to rebuild the motor and put the bike back together?
8 hours give or take
If there something I don't know please inform me I'm lost I have a blown bottom and chunks of metal inside on top my piston and down by my crank no idea could be is Barry's to get the chunks of metal don't look like they're in pieces
These bikes blow up if you don't maintain or eventually rebuilt them. Since metal went everywhere, you need to rebuilt the bottom end. This video will walk you through it.
If I buy it how long will it take you to send it
You get instant access to stream it. I do not send anything in the mail.
Is the rebuild basically the same for a kx 60
Tips/tools/procedures used in this video will help for any 2 stroke. There will be some differences though.
I have a 93 kx 125 and I wanna know does it have a bottom end? If so can some one send me the link for the whole kit
Don't buy a kit. Take it all apart and see what it needs. Buy OEM replacement parts and have stock crank rebuilt.
I have a 95 kx 125. the oil keeps getting water in it, any thoughts?
+robert mckelvey Water pump seal. This video covers it.
Nice
+Justin Scott Thanks!
+MatthewMCRepair Got finished watching this video since it was uploaded, Good Demonstration.
So are you saying, if I have a 2001 KX125, I can put a crankshaft for a 2003 KX125 in my 2001 Bottom End with no problems?
No I never said that. I would look up the crankshaft PN for both years and see if they match. If they do, then yes, you can use it.
hey matthew i was wondering if i could get your top and bottom engine rebuild full video free because i am on a budger for rebuilding
Josh, buy the video, it is worth every penny.
Im about to rebuild a 93 engine will it be the same?
90% will be the same.
I saw a kx 250 on Craigslist for 1000$. It had a full fmf system, did black rims, pro taper bars, renthal sprocket and chain, acerbis hand guards, a wiseco piston still in the box, and v force reeds. It needs new rings and a new piston, which the guy had. And it needed the bottom end rebuilt. Is that a good deal?
+BenTheAwesome 56 I can't tell you whether it is a good deal or not w/o looking at it. I spent 800 rebuilding my engine. Since you have the piston, factor at least 700 for a full rebuild. Make sure to check suspension linkage for wear, brakes, etc... as that all adds up quick too.
+BenTheAwesome 56 depends on what the cylinder looks like. it needs a bottom end one replied 700 for a rebuild? i did my kx 250 i put a tranny in it for 25 dollars the studs for cylinder were bent tapped out some threads new base gasket new front sprocket. i would get for 700.00. what year?
+Kevin Stearns it was a 2004
hey just downloaded the manual... bought my bike with blown motor (Great deal $$) however the motor was mostly tore down and came with a new complete kit. I have trouble indentifying and determining which seals are for what... the package of seals has soo many and the numbers dont correspond with diagram... ive figured out the obvious ones (crank, kickstarter) but need a picture to go with it lol .... any knowledge of the whereabouts of this information?
Aftermarket kit? I find the same issues ID'ing parts. Look in the parts diagram, the part description may have seal dimensions.
MatthewMCRepair ya its a hot rods kit... same bike as you. ill have to do some cross referencing indeed
MatthewMCRepair also when installing the new main bearings the seals must be in first... will the bearings drop in cold or will I need to heat the case aswell? when would the seals go in if this is the procedure? during heat or right before bearing?
Install seals, heat cases up and freeze bearings, and drop them in. Seals will not get damaged in oven. Do not use a blowtorch. This is all covered in detail in the full video FYI.
ya my internet line was chopped at home... trying not to use up my data to rebuild this thing lol... will definitely be watching them all on assembly
If I have zero mechanical skills (the biggest thing I've ever done is brakes and oil change on my car), am I qualified to fix my dirt-bike my friend gave me (before moving) by myself?
Yes the video is step by step and others in your shoes have completed the rebuild.
I’m going to purchase your videos, What’s the app you need?
You only need the app if using smartphone or tablet. The app is "Gumroad".
Does this cover a 1994 klx250r?
No, that is a 4 stroke, completely different.
hey man im about to buy a 125, will a 250 fit if i ever need one :o? thnx!
What is your Q?
hey matthew!
Picked the girl up yesterday
its a Kawasaki KX125 1990 , Old but runs really sweet!
Was wondering if i could fit a 250cc kit on it if i'd ever need it
I think 144 is as big as you can go.
Sooo helpful 🙄
Take it to the shop.....they are helpful $$$$
Is there a second part that just goes slowly through the power valve explanation?
What info are you looking for? The rebuild video covers it in detail.
@@HTMR looking for it to be more explained with voice over. You do amazing videos so it would be helpful!
@@quadsport7022 It is in the full video. Are you doing a top end or something?
Why did you spend 27 minutes taking everything off the bike then fast forward through all of the important stuff
I clearly mentioned that this is a sample video in the beginning.
because its not free and you have to pay for the important stuff, very jewish indeed.
😂😂😂😂its a sample
@@chriseller6402 gets paid twice.... youtube views and commercials and then for purchasing it ......
Fk was the point of making a video if its “a sample video” this isnt a restaurant tf?
Can I use this for my kx 250 1991 ???
Yes, video should be 90% applicable.