Do It Yourself KX250 Engine Rebuild! A Complete Step-By-Step Tutorial

🔥In this video, we're going to show you how to rebuild the KX250 (years 1992-2004) engine yourself! This is a great DIY video for anyone who is looking to save money and do the work themselves.
We'll cover everything from the basics of engines and bottom ends to bearing installation, transmission and crank 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...
🔥LONG Blind Bearing Puller: amzn.to/46S9YsR
🔥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...
🔥Maxima Assembly Lube: www.rockymount...
🔥Blue Threadlocker: amzn.to/47V2eri
🔥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!

[@trentszachnitowski4628]

YAAS! your videos(particularly this kx series) have convinced me to take the plunge into rebuilding my own '02 kx250! pulled the engine yesterday, this video could not have been ANY better timed! love ALL of your videos man, your channel is gonna be HUGE one of these days man. keep up the good work!!

[@GregHitchko]

Heck yeah Trent! Stoked to go along on the journey with you in the KX build! I appreciate the kind words. Taking it video by video 🙌🏼💨💨

[@danpoxon2425]

Hell yeah Greg that engine looks mint

[@GregHitchko]

Thanks Dan! Stoked on the turn out 🙌🏼

[@coreyweese2232]

I like that micro polish. I’ll have to try it on the build I’m doing now. Also that tip on the c clip. Didn’t know that.

[@GregHitchko]

Right on Corey! Crazy how smooth the tranny is🙌🏼. Glad you found some value in the c clip, tip. It's the little things! 💨

[@corvette_jake7225]

You are my hero, kind sir. I will be taking the plunge this week into rebuilding a 2000 kx 250. I've done top ends, but never anything this extensive.

[@rossilake218]

Hi Greg, I hope when you assembled that transmission you oiled everything. If its the trans, use your preferred trans lube. The crank bearings use premix oil, dont over do it, a little goes a long way. There is such a thing as too much, especially grease. I know a leading grease engineer. The oil/grease only needs a thin film on the race. Doesn't matter if you have 10 gallons around the bearing. Grease the seals also. Also use heat and freeze bearings. Also go to Hapless freight and get a bearing/seal driver, the chinese ones are cheap. Use your press, the alignment is almost perfect, better than by hand. I'm building 2 Cr250's. Thanks

[@dcouture79]

I’m sure they will be! These videos are so helpful as I’m building my 99. Education, tips and ideas, awesome. I’ve already got a second transmission boxed up and ready for Millennium haha

[@GregHitchko]

Oh heck yeah! Didn't know you had two transmissions that you were going to send to Millennium! Both for the KX or another bike?

[@dcouture79]

@@GregHitchkoWell, found out the stock output shaft splines are way out of spec after I put the entire engine back together..now I need to pull it all back apart so I figured I might as well have the replacement transmission sent to Millennium before I install it. Because, why not, right? Haha

[@GregHitchko]

@@dcouture79 dang that's a bummer to have that happen but glad to catch it now rather than down the road! And yup, might as well send the second set to Millennium haha

[@tasosridas3288]

Best step by step engine rebuild I’ve seen, Awesome job!!

[@GregHitchko]

Thank you very much for the kind feedback man!

[@ScubaSteveCA]

I’m getting ready to tackle this monster. This video should be the perfect partner

[@GregHitchko]

Right on dude! Let me know if you have any questions. Enjoy the process!

[@Mitchlovin145_mx]

Huge props for the step by step! Thank you, as you know ive done my fair share of lower ends but my 99 kx 250 bike in a box project was Completely disassembled when i got it

[@GregHitchko]

Thanks Mitch! I always appreciate the kind words. I feel your pain as I went through the same thing with the YZ from the shootout. Takes a while to make sure you've got everything you need, and it adds an element of unknown because you don't have the reference from taking it apart! You won't have a problem though, these are cake. All the 250's are pretty similar still as you know.

[@dcouture79]

Love it man! I don’t think I’ve been more excited to watch a video on KZbin. Excellent video and descriptions!

[@GregHitchko]

Haha that's awesome, thanks Derek! Hopefully I can make part 2 and part 3 just as good 😂

[@chrisr.1391]

Let’s go!!!!

[@GregHitchko]

I was worried I didn't give you enough notice in order to catch the live video!! Haha Thanks Chris

[@ccooper04]

About to pick up a 2001 kx250 for cheap and going to need to go thru the engine. I’m looking at doing the transmission like you did along with sending off the crank and jug and letting millennium technologies rebuild the crank and do whatever service is needed for the jug and micro polish the transmission. Just need to find someone to vapor blast the case halves so I’ll be prepared for the assembly.

[@GregHitchko]

Right on dude! I highly recommend all of that stuff. If you're tearing into the engine, you might as well while you're at it. For the vapor blasting, reach out to Tyler Winstead [e-mail]. Let him know you chatted with me and he will give you a deal on the vapor blasting!

[@RobiBrown-eb8lo]

I’m a newbie on your channel. Got my 95 KX 250 apart and engine is on the bench. Really looking hard at the weekend warrior blaster. They’re only an hour away. Trying to persuade my better half to agree. I’m old.

[@GregHitchko]

Right on! I had one and it was $800 to ship it across the country to Utah so you will save some hugee money there. Honestly, for the amount of times you will use it. I would just outsource the work. Unless you plan to turn it into a business and have clients lined up. You'll save thousands, unless you have money burning a hole in your pocket of course lol

[@luismelendez935]

Did you put the circlips in one direction, great video man

[@calebblackwell2160]

Love this series. I'm about to restore a 1998 kx 250 that I've had since I was 14. When you get to it can you show in detail where all the cables are strapped/routed to the frame? Especially the ignition wiring harness. Thanks for this series!

[@GregHitchko]

No problem Caleb! I'll have the bike rebuild video coming soon but until then, search for the tear down of this bike on my channel. I discuss briefly the wire routing, etc! 💨

[@mikeguliz]

love your vids cant find a decent engine builder i have to start buliding my own like you do just a couple years older🤙

[@GregHitchko]

Right on dude! I support that move. it's all about taking your time, having the right tools, and having fun with it. That's the combo right there haha

[@Thepianobird]

so sick. I want to do all this to my 03 yz250. it would be cool to have a parts tumbler so you can polish various parts including your gears....

[@GregHitchko]

Heck yeah make it happen dude! Some day a parts tumbler would be a nice addition to the garage for sure 🙌

[@artlizarraga677]

Thank you very much for this information this video has helped me tremendously

[@GregHitchko]

That is great that this video was able to help you out! Thank you for the feedback. I hope the build went together smoothly for you.

[@Nickray-np3bm]

6:10 where did you sorce these bearings from ? Did you ever replace the bearing all the way to the left in the case ?

[@TimG-z7u]

Hey Greg, I’m looking at purchasing a 96 that needs a rebuild. Do you have a rough idea what I could expect to pay for all the tools and parts? Thanks in advance

[@niconine268]

Damn did i just miss it ? Got the '05

[@GregHitchko]

The power valves are different but it's pretty much the same process that would apply to the 2005 engine. They are not much different! I do have a tear down video of the 07 kx250 engine on my channel however that you can follow Tear down - kzbin.info/www/bejne/bIW5haKFd6uco5Y Bottom end rebuild - kzbin.info/www/bejne/g3iQZISMrpeba6M

[@liekz3264]

Is it okay to use permatex as gasket between the cases?

[@garycrites]

Thanks for the detailed video, Greg. I’m going to follow your lead on removing the clutch bearings. I checked out your link for the extended bearing puller collet but it seems to be taking me to a different product. Is the link correct? Thanks in advance!

[@GregHitchko]

Not a problem Gary! Glad the video can help out. Unfortunately I couldn't just find the collet, I had to buy the kit as a whole. I cringed to spend the money on it but for the piece of mind, it was worth it. It worked great too. Here it is just to confirm amzn.to/46S9YsR

[@kennethneathery3963]

Hey Greg, Ken man here. A follow up from past thread: Blue monster makes good copper and Nickle anti seize & thread sealers. I need to add that I recommended copper past for pipe sealing. Not accurate in some applications. Nickel based for stainless and titanium to prevent corrosion that copper will cause on those metals. So use nickel. copper has good conductivity properties. Spark plug, battery, ground post att. Just consider metallurgy in choice making. Nikel conducts well also. kzbin.info/www/bejne/nGfEnJavq9aosNU A good info vid. Another product line is CRC and CRC Marine. Benchmark stuff. Use CRC Marine conductive lithium grease for AII wire plug connections and termination. Even in crimp connectors. No fail good practice. CRC is the best period. Merry Christmas and a blessed New year. Kenman

[@Queeratron]

@GregHitchko My transmission spins free but as soon as i bolt the cases together it doesnt spin. Do i just need to split the cases again and seat the bearing better? Thanks!

[@zodzod9378]

yep nice job dude ! Little john from the UK

[@GregHitchko]

Thank you very much little John! I always appreciate the input 🙌🏼💨

[@juancisneros6833]

Would a kx 250 f 09 engine be just about the same

[@bdon8366]

My 99 kx250 has had been sitting up for 10 years, I finally decided to rebuild the engine. And every time I mate the cases while doing a dry run the transmission won’t spin freely once bolted up. I even mated the cases with only the shaft that holds the sprocket and it won’t spin freely. Any suggestions?

[@GregHitchko]

Nice!! Stoked for you that you're rebuilding it. Does the transmission spin freely before you put that second case half on?!

[@niconine268]

Hi Greg. I have the 05 & no manuel. Do you have a pdf for this ?

[@MeRzYLoRd]

Can you provide link for the kit?

[@GregHitchko]

Sure man! What kit are you referring to?

[@janirepo587]

Very informative and helpful video. Is there a lot of difference to a KX 2007 model? My -07 is waiting for rebuild also.

[@GregHitchko]

All two strokes are going to be pretty similiar to this actually! But I do have an 05-07 specific bottom end rebuild video on the channel right here. The main difference is the shifting mechanism I'd say. kzbin.info/www/bejne/g3iQZISMrpeba6M

[@wrecked3362]

do you have a link to the extended bearing extractor for the clutch actuator arm? Thank you great video as always.

[@GregHitchko]

I felt like I was missing something from the list! Thanks for the reminder dude. Here it is! amzn.to/46S9YsR

[@CalebLove-ci8bv]

Appreciate the video! I had a quick question. Just pulled the cases back together on my brothers yz85. Installed new bearings and crank. The crank rotates very smoothly (no tight spots/binding), but its not necessarily super "free", if that makes sense. Like it's a bit tight, but not to the point where I can't rotate with my hands; and like I said, it's still rotates very smoothly. It basically has a bit of drag to it. I was watching some other videos and people were saying that as long as there is no binding, it should be all good, even if the crank is a bit tight, as it will kinda "wear itself in". Of course it may be hard to tell from just this comment, but do you have experience with cranks being a bit stiff (or a situation like mine), where the bike ends up running fine?

[@cdog2145]

Hey man I am struggling to find a 2006 crank for my 250! Where did you get yours? Many thanks callum. Good work 👍

[@GregHitchko]

I feel like this conversation sounds familiar lol, do you not have a crank at all?

[@cdog2145]

@@GregHitchko it appears to be that way! I have the crank but the nilon bungs burnt out in the centre! Managed to get one now from Holland! Kawi didnt make complete cranks from 06 upwards I think

[@TH3_T3RM1N4T0R]

Hi Greg, I tried to mail you with regards to the service manual, but the message unfortunately bounced back. Any chance I could still get it? I've got a '99 too, and appreciate the videos, they are an excellent resource. Thanks for sharing.

[@GregHitchko]

Hey dude, try it again! Here is the email to confirm [e-mail]

[@TH3_T3RM1N4T0R]

@@GregHitchko thanks Greg, will do.

[@janirepo587]

On 7:22 in this video you have two screws there to hold that bearing, but in the Kawasaki manual there´s only one. Also i had only one screw to hold it when I tear my engine. Should i put it with two screws now when assemble engine back together?

[@GregHitchko]

Great question, what year is your bike? Also, are there two holes for two retaining bolts to screw into?

[@janirepo587]

@@GregHitchko 2007, I just watched your another video from -07 rebuild and there was only one screw also in upper hole and lower hole had another one with some gear shift mechanism to hold together. So problem solved!

[@GregHitchko]

@@janirepo587 golden!! Yeah the cases changed from 02 and on so that definitely makes more sense! Glad you figured it out, now I know for next time as well. Thanks dude!

[@05ALT]

Hey, what mixing ratio and fuel do you use in your 2 stroke bikes?

[@GregHitchko]

I run them 32:1 with maxima castor 927! www.rockymountainatvmc.com/parts/maxima-castor-927-2-stroke-oil-p?ref=1057

[@kennethbailey1668]

@greghitchko where did you find the two bearings with the lip? Or whats the part number on tokyo bearings website.

[@GregHitchko]

Hey dude! You can grab all of those bearings from RMATVMC, that's where I got mine aside from the ProX crank bearings (Koyo). www.rockymountainatvmc.com/oem-schematic/0?ref=1057

[@mareksumguy1887]

You don't use assembly lube in wet clutch gearbox. You use just motorcycle oil.

[@seththegamer200]

how similar is this to the kdx200??

[@GregHitchko]

All of these two stroke engines are very similar. You can follow these videos along with the KDX manual and you can for sure rebuild that thing!

[@seththegamer200]

@@GregHitchko cool man, I've just put the cases back together and the crank is really stiff... Any recommendations?

[@someoneyouknow96]

WTF! No notification on your new video. Damn KZbin needs to get their shit together.

[@GregHitchko]

Hahaha two videos actually! This one and part 2 of the engine rebuild

[@someoneyouknow96]

@@GregHitchko i know. I didnt have time to watch the 2nd one

[@ArthuroCabezas1975]

Hello papi all look too excellent 🫡

[@Factory928AC]

🤟🏽

[@GregHitchko]

Cheers mate! 🔥

[@TimG-z7u]

Hey Greg, I’m looking at purchasing a 96 that needs a rebuild. Do you have a rough idea what I could expect to pay for all the tools and parts? Thanks in advance