DIY KX250 Engine Rebuild PART 3 - Top End and Power Valve Rebuild

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🔥Part 3 of a 3 part Kawasaki KX250 Engine Rebuild series for 1992-2004 models. This is a great DIY video for anyone who is looking to save money and do the work themselves.
We'll cover everything about the TOP END of the engine including the correct way to install the power valves, piston and ring preparation, piston installation, cylinder installation, and cylinder head installation. This is a STEP-BY-STEP guide, so you'll be able to rebuild your KX250 top end without any problems.
This is a great project for anyone who is looking to learn more about motorcycle mechanics and restoration. Make sure to check out our video tutorial and learn how to rebuild the KX250 engine yourself!
Email me at hitchkomoto@gmail.com for a copy of the PDF manual to reference.
These are the tools and materials you will need to help you rebuild the engine below:
🔥Engine Stand: www.rockymountainatvmc.com/pa...
🔥Torque Wrench Adaptor: www.rockymountainatvmc.com/pa...
🔥Engine Lock-Up Tool: www.rockymountainatvmc.com/pa...
🔥Clutch Holder: www.rockymountainatvmc.com/pa...
🔥JIS Screwdrivers: www.prymemx.com/collections/t...
🔥Stud Installer / Remover: www.rockymountainatvmc.com/pa...
🔥Maxima Assembly Lube: www.rockymountainatvmc.com/pa...
🔥Blue Threadlocker: amzn.to/47V2eri
🔥Crank Installer: www.rockymountainatvmc.com/pa...
🔥KX250 Crank Puller Adaptor: www.rockymountainatvmc.com/pa...
🔥Thread Chaser 6mm: amzn.to/3RlX8gz
🔥Circlip Pliers: www.rockymountainatvmc.com/pa...
🔥Torque Wrench: www.rockymountainatvmc.com/pa...
🔥Infrared Thermometer: amzn.to/48kbGV3
🔥Brass Punch: amzn.to/46WxuVq
🔥Condiment Bottle: amzn.to/4agm8i3
🔥Castor 927: www.rockymountainatvmc.com/pa...
🔥Yamabond 4 Liquid Gasket: www.rockymountainatvmc.com/pa...
Cleaning Two Stroke Exhaust Valves: • HOW TO: Clean Two Stro...
1999 Splitfire Rebuild Project:
Engine Tear Down Part 1 Video: • See How Easy It Is To ...
Engine Tear Down Part 2 Video: • 92-04 Kawasaki KX250 E... E
1999 KX250 Splitfire Rebuild Series - Part 1: • New Two Stroke Project...
1999 KX250 Splitfire Rebuild Series - Part 2: • SOS I Need Your Help |...
OEM vs PC Kit Suspension: • The Shocking Truth: Pr...
🔥SOCIAL MEDIA:
Instagram: / greghitchko
🔥EMAIL hitchmotoko@gmail.com with any questions or inquiries
🔥MAXIMA 80W MTL TRANSMISSION OIL: www.rockymountainatvmc.com/pa...
🔥MAXIMA COOLANOL: www.rockymountainatvmc.com/pa...
🔥MAXIMA QUICK MIX CUP: www.rockymountainatvmc.com/pa...
🔥MAXIMA SUPER M PREMIX: www.rockymountainatvmc.com/pa...
****TOOLS****
🔥DEWALT IMPACT GUN: amzn.to/3wQgTl8
🔥DIGITAL CALIPER MEASURING TOOL: www.rockymountainatvmc.com/pa...
CERAKOTE TRIM COAT: amzn.to/3hPfm8P
MUSIC:
EPIDEMIC SOUND www.epidemicsound.com/referra...
This video is NOT sponsored. Some product links are affiliate links which means if you buy something I'll receive a small commission. Thank you for supporting the channel!

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Опубликовано:

3 авг 2024

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Комментарии : 67

@zurqsbetter7652 5 дней назад

Thank you so much man you helped me restore my 03 kx250 I got a brand new crank and piston in it because of you and now it runs for the first time in years you helped so much I can’t thank you enough !!!

@Kawasancho 4 месяца назад

Thank you so much! You saved the TV and and my jug because that thing was a second away from getting launched.

@GregHitchko 4 месяца назад

😂😂 I'm glad the TV and jug are fine. As well as yourself hopefully haha

@bobbybailey2244 6 месяцев назад

Thanks to your videos I have successfully rebuilt my 1999 KX250. I’ve completely restored this bike and I could easily do everything but the motor myself. I wasn’t familiar with 2 stroke motors so if it wasn’t for you I would’ve been lost. THANK YOU! you helped me succeed in the final but most important part of my restoration. I literally learned everything from you!

@GregHitchko 6 месяцев назад

Dude this is amazing Bobby! Hearing things like this is truly why I make these videos. 🙌🏼 I try and pass along the things I've learned over time to help others, just like they've helped me. Thank you for the feedback and pumped for you to restore your 99!!

@bobbyblenio4571 Месяц назад

You have a Beautiful Sickness Greg,I been watching the Build of this Bike…Good Job🤘🏁🔥

@GregHitchko Месяц назад

Haha thanks Bobby! Sickness is a great way to describe it, I apprecaite you following along!

@jerryhill4893 2 месяца назад

Great job. Thanks

@GregHitchko 2 месяца назад

Hope it helps my dude! Thanks

@mangopie1787 6 месяцев назад

Badass! Thanks for taking the time to break down the install with so much detail, every other video i watched has terrible camera angles and rushes through the process, i found this video very helpful

@GregHitchko 5 месяцев назад

Right on! I appreciate that feedback. That was the goal with this video. I really wanted to break it down in simple terms and shots that you can actually see haha. Cheers!

@knotraffik2967 5 месяцев назад

Very informative and thorough! Might be one of the best videos Ive seen to date!

@GregHitchko 5 месяцев назад

Thanks for the feedback my dude! I can definitely improve but I tried to break it down as simple as possible💨

@brettlaage9687 6 месяцев назад

So many more parts to the power valves than a Honda has. I don’t own a Kawasaki, I just enjoy watching your videos. I can’t wait to see this one all complete.

@GregHitchko 6 месяцев назад

Oh yeah! Especially the 02-07 CR250's. But then again you've also got the RC cable set up to deal with. Thanks for watching Ryan, I really appreciate it man!

@ryanphillips3916 6 месяцев назад

Super clean build!! Can’t wait to hear it run!!

@GregHitchko 6 месяцев назад

Thanks Ryan! That will be coming up really soooon!

@chrisr.1391 6 месяцев назад

Let’s go!!!! 💨💨

@GregHitchko 6 месяцев назад

Let's go Chris!!!

@Jone5y 6 месяцев назад

Great work I’m doing a Kx 250 2004 il be working along your videos thank you!

@GregHitchko 6 месяцев назад

Right on! Sounds awesome my dude, keep me posted on it 🙌🏼💨

@HTMR 6 месяцев назад

Hey Greg nice vid! I think your audio is "clipping" as I hear ticking/popping. Let me know if you need help from a fellow RU-vidr 😊

@GregHitchko 6 месяцев назад

Cheers dude thank you! Let me know at what time stamps you are hearing it because it's not doing that on my end. First time I've heard anyone say that actually!

@GregHitchko 6 месяцев назад

I do hear it slightly near the end of it! Never had that happen before. Doesn't seem bad but a trained eye will hear it haha

@AM-365 6 месяцев назад

The last 4 videos the audio has played up on my side.

@HTMR 6 месяцев назад

@@GregHitchko its really the whole vid, and some of your older vids as well. What is your audio recording setup and post editing process?

@GregHitchko 6 месяцев назад

@@HTMR I use Rode lav mics and then I edit in iMovie

@derekvalenzuela492 6 месяцев назад

Shes mint! Bikes gunna be sick!

@GregHitchko 6 месяцев назад

Thanks my dude!

@1187titanium 6 месяцев назад

With the expanding t gauges you wanna extend and lightly tighten them while tilted on an angle then pivot to the opposite angle while removing and that will ensure repeat-ability of accuracy

@GregHitchko 6 месяцев назад

I appreciate you leaving that tip with using the T gauges! Makes sense for sure 👍🏼

@KIPSSYTEM 6 месяцев назад

Thanks so much Greg! I’m in the middle of rebuilding the 93 kx250, and man I’m very close to being finished, then I see your your videos man they have saved me so much time. also I have these transmission bearings giving me problems I’m about to weld my bearing puller to them any ideas?, I also can’t seem to get the lock tight bolts that keep some of the bearings in place out, im about to pay an hour or 2 for a shop to pull them😅😂

@GregHitchko 6 месяцев назад

Heck yeah dude! Stoked the videos can help you out🙌🏼. You'll need two things to get those bearing retaining screws out. An impact screw driver and lots of heat to break up the loctite. For the bearing puller, you need to make sure that the collet is tightened down really tight so it catches on the inner race really well. Put the cases in the oven and bake them for a while. Until they sizzle with water. Once you do that, it'll be much easier to get those bearings out as well. Face the case down and they may even fall out on their own!

@danpoxon2425 6 месяцев назад

Man that engine looks sweet as a nut!

@GregHitchko 6 месяцев назад

Thank you my dude!

@1187titanium 3 месяца назад

That power valve guide you mention at 2 min... i just had to have one custom made because my cylinder didnt come back from plating with it

@user-gc3pp5wd7d 3 месяца назад

Огонь! Подари мотоцикл

@mordauntbrabner3804 6 месяцев назад

Super informative vid. I am rebuilding a 2001 KX-250 engine. Need a new power valve shaft if anyone has one sitting around?. Thanks.

@GregHitchko 6 месяцев назад

Thank you for the feedback my man! We will definitely keep our eyes out for you on that power valve shaft.

@davidchaney8967 5 месяцев назад

I got the same gasket kit u have where does all the o rings go the rubber on3s

@stormslo 4 месяца назад

I just redid the top end, and with the head gasket off when I move the kick start...it kind of gets stuck and impossible to move at the lowest point of the piston. The piston itself is moving super smooth, should I check the Kickstart or bottom end?

@zodzod9378 6 месяцев назад

Greg thats engine porn nice job dude so much easier when the parts are so clean i found on my RM! Little john from the UK

@GregHitchko 6 месяцев назад

Haha that's a true story! Thanks Little John!

@rockman49er 3 месяца назад

My motor doesn't have the rubber boot thingy on the power valve arm where you cut the gasket 😮 mine is a 98kx250

@brysonhudson2943 3 месяца назад

Do you have a complete parts list that you used for the rebuild?

@Sparky78739 21 день назад

Hi, can you please send me details for new head studs, I can't find anything here in Australia

@someoneyouknow96 6 месяцев назад

It popped up this time!!!!!!!!!

@GregHitchko 6 месяцев назад

Haha yes!!! Glad it did 😂🙌🏼

@someoneyouknow96 6 месяцев назад

@@GregHitchko me too. Good video. Someday ill need to rebuild my kx.

@GregHitchko 6 месяцев назад

Keep me posted when you do!

@someoneyouknow96 6 месяцев назад

@@GregHitchko hopefully its a long time from now. When I bought it, it had 190psi on 5 kicks. It had been rebuilt by the previous owner to the guy I bought it from. The guy I bought it from had 5 bikes so it got very little use. When I tore it down I looked down the spark plug hole and read the numbers on the top of the piston. Its got a wiseco piston in there. It smokes like crazy and I cant figure out why but it runs great. I've jetted it to spec and leaned it out even more and she still spooges all over my swingarm. But she runs and I ride it at the vmx races I can make it to.

@nietgebruiktsins2016 4 месяца назад

which spark plug are u using

@garycrites 6 месяцев назад

Did you use Tungsten cerakote on the valve covers?

@GregHitchko 6 месяцев назад

I used burnt bronze on the valve covers but would have actually preferred something a little darker for next time!

@diiegovirgilioo5860 6 месяцев назад

Hello, I have a question, I have a Kawasaki 250 2-stroke from 2003 and I have seen that one of the valves moves and the other does not, is that normal in those engines or should I check well?

@GregHitchko 5 месяцев назад

Hey dude! Yeah that is definitely not normal, both of the valves should be opening and closing simultaneously, at the same positions, at the same rate. I would tear down the valve set up and see what's going on. My guess is that the timing is off on it! Keep me posted on it

@RobiBrown-eb8lo 29 дней назад

Hey Greg, I watched your entire videos on this engine build. I have a 95 KX 250 that only had a year on it so it was in really nice shape but it sat so long. I noticed one of my teeth on those 2 valves? was one tooth off. I was wondering if you have heard of this before. If I time it like you did it’s not opening or closing like it should. I have a ways to go on it. Thanks man, I don’t think you realize how much you’re helping people like myself.👍

@RobiBrown-eb8lo 29 дней назад

I bought it new by the way.