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

[@zurqsbetter7652]

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 !!!

[@GregHitchko]

@@zurqsbetter7652 dude what an awesome story! So stoked this video was able to help man, congrats on the rebuild!

[@bobbybailey2244]

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]

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!!

[@mangopie1787]

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]

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!

[@xxnickthegreekxx]

I’ve seen a lot of these videos for this model bike and I like the fact you gave torque specs for pretty much everything also there’s things you do different from myself which I like. Currently watching this as my bike has sat for 3-4 years and is now stuck in gear so I’ll be splitting and going through as meticulously as you have here.

[@Kawasancho]

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

[@GregHitchko]

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

[@HTMR]

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 KZbinr 😊

[@GregHitchko]

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]

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]

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

[@HTMR]

@@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]

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

[@brettlaage9687]

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]

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!

[@bobbyblenio4571]

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

[@GregHitchko]

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

[@knotraffik2967]

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

[@GregHitchko]

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

[@ryanphillips3916]

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

[@GregHitchko]

Thanks Ryan! That will be coming up really soooon!

[@wateronfirefk]

Awesome video , def life saver 👍

[@Jone5y]

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

[@GregHitchko]

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

[@jerryhill4893]

Great job. Thanks

[@GregHitchko]

Hope it helps my dude! Thanks

[@brysonhudson2943]

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

[@chrisr.1391]

Let’s go!!!! 💨💨

[@GregHitchko]

Let's go Chris!!!

[@davidchaney8967]

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

[@1187titanium]

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

[@nietgebruiktsins2016]

which spark plug are u using

[@stormslo]

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?

[@derekvalenzuela492]

Shes mint! Bikes gunna be sick!

[@GregHitchko]

Thanks my dude!

[@garycrites]

Did you use Tungsten cerakote on the valve covers?

[@GregHitchko]

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

[@Sparky78739]

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

[@mordauntbrabner3804]

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]

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

[@1187titanium]

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]

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

[@KIPSSYTEM]

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]

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!

[@rockman49er]

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

[@diiegovirgilioo5860]

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]

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]

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]

I bought it new by the way.

[@danpoxon2425]

Man that engine looks sweet as a nut!

[@GregHitchko]

Thank you my dude!

[@someoneyouknow96]

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

[@GregHitchko]

Haha yes!!! Glad it did 😂🙌🏼

[@someoneyouknow96]

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

[@GregHitchko]

Keep me posted when you do!

[@someoneyouknow96]

@@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.

[@Олег-п3ь7л]

Огонь! Подари мотоцикл

[@zodzod9378]

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]

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