DIY KX250 Engine Rebuild PART 2 - Clutch, Shifting Mech, Kickstart Assembly, Water Pump, Flywheel

🔥Part 2 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 right and left sides of the engine including the shifting mechanism and shift shaft, idler gear, kickstart assembly, complete HINSON clutch install, primary gear, water pump impeller, stator, and flywheel installation. This is a STEP-BY-STEP guide, so you'll be able to rebuild your engine 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 [e-mail] 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.rockymount...
🔥Clutch Holder: www.rockymount...
🔥Engine Lock-Up Tool: www.rockymount...
🔥JIS Screwdrivers: www.prymemx.co...
🔥Stud Installer / Remover: www.rockymount...
🔥Maxima Assembly Lube: www.rockymount...
🔥Blue Threadlocker: amzn.to/47V2eri
🔥Crank Installer: www.rockymount...
🔥KX250 Crank Puller Adaptor: www.rockymount...
🔥Thread Chaser 6mm: amzn.to/3RlX8gz
🔥Circlip Pliers: www.rockymount...
🔥Torque Wrench: www.rockymount...
🔥Infrared Thermometer: amzn.to/48kbGV3
🔥Brass Punch: amzn.to/46WxuVq
🔥Condiment Bottle: amzn.to/4agm8i3
🔥Castor 927: www.rockymount...
🔥Yamabond 4 Liquid Gasket: www.rockymount...
🔥SOCIAL MEDIA:
Instagram: / greghitchko
🔥EMAIL [e-mail] with any questions or inquiries
🔥MAXIMA 80W MTL TRANSMISSION OIL: www.rockymount...
🔥MAXIMA COOLANOL: www.rockymount...
🔥MAXIMA QUICK MIX CUP: www.rockymount...
🔥MAXIMA SUPER M PREMIX: www.rockymount...
****TOOLS****
🔥DEWALT IMPACT GUN: amzn.to/3wQgTl8
🔥DIGITAL CALIPER MEASURING TOOL: www.rockymount...
CERAKOTE TRIM COAT: amzn.to/3hPfm8P
MUSIC:
EPIDEMIC SOUND www.epidemicso...
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!

[@ArthuroCabezas1975]

Hello papi was the best explanation for the assembly the clutch system…. Paz ✌️

[@dcouture79]

Love the video!! Used it tonight and found 4 issues from my previous assembly! I also thought I had an issue with my transmission install because it wasn’t shifting great while bench testing. Then I watched that part of your video again and it’s was exactly the same! Thanks for all the detailed videos!! 🔥🔥😎

[@GregHitchko]

Couldn't be happier that the videos helped you out my man! Like you said, with the videos along with the manual, you can't go wrong. Engine is looking great, now get it back in the bike haha

[@bradkaberline5828]

The pro circuit case covers cool the boyson case cover had some with a works look not polished and a cool fab look been a while I think you could get them in black or a rustic metal look. Henson made the black cover as well I believe the pro circuit works pipe showed the welds not polished good look

[@jerryhill4893]

Your smoove. Nice work. Thanks

[@GregHitchko]

Thanks man! Hope it helped!

[@zodzod9378]

Good job Greg ! Little john from the UK

[@GregHitchko]

Thank you as always little John! You the man

[@wrecked3362]

Great video as usual thank you!

[@GregHitchko]

Cheers dude! Thanks for the feedback 🙌🏼

[@ryanphillips3916]

Don’t mix up the assembly lube and loctite!!!

[@GregHitchko]

Haha that's a great point right there!!

[@chrisr.1391]

Oh yeah… let’s go!!!

[@GregHitchko]

You the man Chris! Thank you as always 🙏🏼💨

[@chrisrieger9201]

Out of the 250’s which one is the most enjoyable, easiest to rebuild

[@GregHitchko]

Great question! This one has the easiest bottom end, because the shifting mechanism is simpler than the newer models. The only real difference is in the power valves, I think the 05-07 KX250 was the easiest out of the rest. The CR250 wasn't bad either but setting up the RC valve and getting it correct is annoying lol.

[@chrisrieger9201]

@@GregHitchko yes I’ve seen that with the cr’s. Great work, I never could do that, you differently have a calling for it. Are you for hire??

[@Journeyman1642]

Shift shaft seal 😳

[@josephoneal7960]

What’s the part number for the bolt kit

[@2strokelover93]

Clean

[@GregHitchko]

Cheers dude, thank you 💨

[@garycrites]

Hey Greg On the Pro X fiber and plate kit there are no blue and red markings. Would that mean that all fibers are identical?

[@GregHitchko]

Yes! It shouldn't matter which fibers go where, just make sure you start and end with a fiber 👍🏼

[@garycrites]

Thanks Greg! Almost there

[@garycrites]

After installing the fibers and plates I noticed a clicking noise when the idle gear rotates, it’s contacting the spring on the shift shaft. The shift shaft is pushed all the way in. Is that normal?

[@andrewwilson9130]

what color is that on the inner clutch cover?

[@GregHitchko]

It's Tungsten cerakote 👍🏼💨

[@andrewwilson9130]

@@GregHitchko thanks!!

[@Factory928AC]

This is elite 🫡

[@GregHitchko]

I appreciate the kind words my dude. I also think this is Adam Cianciarulo every time with that avatar picture 😂💨

[@Factory928AC]

@@GregHitchko haha it’s my first and last name but yes that is his logo! 🤭🫣