1991 Kawasaki KX/KDX 250 full rebuild

1991 KDX250 D1-E .... First of the short lived KDX250s. Not to be confused with the KDX250 SR these engines were based off of a 1988-90 KX250 accept with a much hevier fly wheel, larger magneto to supply lighting and a wide ratio gearbox..
I bought the bike for $600 in a box after previous owner blew it up putting to smaller piston in it. Several months later (due to funds always being short!) Shes finally a goer!
Full strip and rebuild bar the plastics and wheels. Cut alot out and sped up alot so the video wasnt as boring!

[@grizdeluxe]

I have a '92 KDX 250. It's the perfect bike for me. I ride desert, woods, and sand. It's a great bike. Congrats on your build!

[@purebloodheretic4682]

Bloody Legend!! I had a '91 KX250 it Ripped! Always loved the Blue Anodised Forks & Perimeter Frame on that Bike! -Cheers👍😉🇦🇺

[@Ottopaul484]

Very nice rebuild, congrats!

[@HURRICANE44]

Top work Ian, i have currently fully restored x3 97 kx250s so i know how much of a chore these bikes can be. I am looking at my next project which is finding a road legal kdx200 220 or 250 to transplant one of these 97 - 98 kx250 motors i have into. Dont see many KDX these days popping up with rego tho.

[@itsrcp1700]

Nice work Ian, pleasure to watch how this beauty got the love

[@wayner1147]

Absolutely beautiful

[@devastator226]

I have 1991 kx125 chassis with a 89 kdx 200 engine . Love that bike !! My wife rides it I ride a 07 kx250 2 stroke !!! Team Green

[@ArthuroCabezas1975]

Very good jop brother you are the best. ✌🏼

[@lucienlagrange38]

Great job !

[@dogchopz]

Hi Can you tell me what full exhausts fit on this bike? Like the older kx spannies etc? Fancy an old pro circuit etc but unsure of compatibility? Cheers

[@AlexGarcia-ew2fv]

The kdx 250 is a great woods n trail bike..I've riden them both n I'd say it has about 25% less power n pep.then the kx250 mx racer....but for woods riding its excellent

[@itfzoran]

Bravo!

[@WHITEKID224]

We’re did you get the plastics

[@Алексей.Эндурист]

За старания респект, но красить раму баллончиком на внедорожном мотоцикле, это усилия впустую, надолго такого покрытия не хватит.

[@MegaYogib]

What silencer is that?? Kx unit?? I just got a 93 kdx250 and the silencer is horrible. I'm gonna run the 02 kfx250f rear fender. Heard a kx250 head gasket gives more compression. Probably do race tech gold valves. Kx500 mototassanari,and fmf fatty pipe.Nice work.😀

[@fletchAlmighty]

Its a FMF Turbinecore but says ISDE special next to it. She now has a FMF gold series expansion pipe too! Good luck with your build man

[@fletchAlmighty]

Ah and yes mate they are few an far between to find as they were for like a 1987 kx250 but its a 0.26 head gasket Im running.. or have your head machined so you can run a more common sized gasket!

[@trevorbettis9492]

What website did you use to find all the parts I can't hardly find anything for my 1992 kdx 250

[@fletchAlmighty]

Hey mate. I use any online parts finder. Fowlers Yamaha UK has a great parts finder, when you click onto a part you want it'll show you what other models and years it will fit. Then use the parts number on Google or ebay to find your parts... The KDX250 is a tuned down 1987-91 KX250 engine. So everything that goes in those year engines also go into yours even if the parts numbers don't always correspond. I'm putting my motor into a 1993 KX frame and swingarm in the next few weeks, already tried it all out, everything fits bar the plastics and tank.

[@lodougherty]

What is your jetting on this bike if you don't mind me asking?

[@fletchAlmighty]

Sorry, I don't remember! I think it was somewhere the same as a KX250 of the same year, as I used a larger KX carb

[@stevejobs5100]

Where did get parts got same model in my garage been trying to restore it for 2 years called 3 different kawasaki branches they got like 2 things for the bike left

[@fletchAlmighty]

Hi Steve. All of the engine parts for the 91 KDX D1 (not necessarily the SR model) are the same as 1988-90 KX250 parts. So the engine is easy. Things like the bearings and crank kit are the same in all KX250 models... I like to google search a online parts finder where you can see the exploded diagrams of your bike. I then search google and ebay for those part numbers. Sometimes just becasuse the part numbers arent the same doesnt mean they dont fit.. So thankfully the KDX250 D1 being so simular to the very popular KX250 parts are plentiful... Just not the plastics! Cant find new ones anywhere!

[@lilithcavalierex7782]

Hey man do you have any parts left over for it you'll sell

[@fletchAlmighty]

No sorry

[@afull-tz3jj]

Hi how many hp ?

[@ishanthapriyankara9913]

♥️👌👌👌👌👌🌟🌟🌟🌟🌟🌟🌟🌟🌟🌟🌟🌟🌟🌟😍 THE BEST KDX 250SR FULL REBUILD VIDEO IN KZbin.....😍♥️🌟👌👌👌👌👌 & SUPERB WORK BROOOOO 🙂🙏⭐🌟🌟🌟🌟🌟🌟🌟👍

[@julianramos757]

Where did you get the plastics

[@fletchAlmighty]

Hi mate. I have found a full set of plastics on ebay brand new but they are very expensive.. I used my original plastics just wet and dryed them down with sand paper then used a heat gun gently to seal the plastics

[@ktmkeith13]

Rockymountainatvmc.com has so so many parts for all Mx bikes- ive used them a lot .

[@ktmkeith13]

Very nice kdx sounds good

[@kingkong81icloud]

I loved my KDX an I had a KMX 200 , not as good as the KDX

[@Φοίβοςβαρθαλιτης]

How it cost you?

[@fletchAlmighty]

$600NZD to buy, about $1900NZD in parts so $2500 all together. About $1700USD

[@Александр159-п4ф]

с балончика -да потянет на продажу...