HOW TO: KX250 BOTTOM END REBUILD - 2007 KX250 Build Part 6

In this video, I go over how to rebuild a Kawasaki KX250 two stroke bottom end. It is a step by step process to rebuild the bottom end of the engine. Leave a comment below about what you think about the all silver motor thanks to the Pryme pads. Click on the links below to make moves on your bike! The service manual to rebuild the motor was a great help. I share the link to ebay to the same manual that I used to help me, especially with torque specs and the transmission!
KX250 Service Manual: ebay.us/OUa7kv
🔥SOCIAL MEDIA:
Instagram: / greghitchko
🔥EMAIL [e-mail] with any questions or inquiries
Looking for parts and tools?! Rocky Mountain will no doubt have them in stock. Check out the links below for all of the tools and products used in the video.
🔥RMATV/MC OEM Parts: www.rockymount...
🔥MOTION PRO TORQUE WRENCH ADAPTER: www.rockymount...
🔥MAXIMA 80W MTL TRANSMISSION OIL: www.rockymount...
🔥MAXIMA COOLANOL: www.rockymount...
🔥MAXIMA QUICK MIX CUP: www.rockymount...
🔥MAXIMA SUPER M PREMIX: www.rockymount...
🔥RATIO RITE MEASURING CUP: www.rockymount...
****TOOLS****
🔥DEWALT IMPACT GUN: amzn.to/3wQgTl8
🔥DIGITAL CALIPER MEASURING TOOL: www.rockymount...
🔥TUSK STEERING STEM BEARING INSTALLER: www.rockymount...
🔥TUSK CLUTCH HOLDER: www.rockymount...
🔥TUSK CRANKCASE SPLITTER: www.rockymount...
🔥TUSK FLYWHEEL PULLER: www.rockymount...
🔥TUSK CRANK PULLER/INSTALLER: www.rockymount...
🔥TUSK BEARING REMOVAL TOOL: www.rockymount...
🔥MOTION PRO STEERING BEARING RACE DRIVER: www.rockymount...
🔥BENCH BUFFER: amzn.to/3tEmFG1
🔥PRYME CLEANING WHEEL PACK - 8 Inch: www.prymemx.co...
PRYME FIBER FLAP WHEEL PACK: www.prymemx.co...
🔥DREMEL: amzn.to/3lJal4L
🔥DREMEL MINI WIRE BRUSHES: amzn.to/3An55bq
🔥EAGLE ONE ALUMINUM WHEEL CLEANER: amzn.to/3BCCVdO
🔥WIRE BRUSHES: amzn.to/37rtLTB
🔥WIRE TUBE BRUSHES: amzn.to/3fHw35q
🔥MAP GAS TORCH: amzn.to/2RIbvR7
🔥BREAKER BAR 1/2' DRIVE: amzn.to/39vErC7
🔥STRIPPED BOLT HEAD REMOVER SOCKET SET: amzn.to/3cQXWHf
🔥MOTOSPORT ENGINE STAND: www.rockymount...
CERAKOTE TRIM COAT: amzn.to/3hPfm8P
Use GREG10 to save at PHATHEAD RACING HEADS: lukesracing.co...
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!

[@fatfightingbros9639]

Finally someone who shows how to do the bottom end, I’ve never taken a motor apart but when my 2002 kx250 died on me I want to try to rebuild it myself

[@GregHitchko]

Hell yeah dude! Definitely give it a shot. You should totally be able to do it. Same thing I thought, there was no one that has fully shown a kx250 bottom end!

[@weebinniec]

Honestly the best video I’ve watched on KZbin this year. Now can you do a video for a bottom end rebuild on an 82 kx 250 85 rm 250 😁 I’m thinking there’s not much more to them going with what you’ve just shown us. Great video well made Legend 😎

[@GregHitchko]

I appreciate the kind words! Send me your engine and I'll make a video ;)

[@weebinniec]

Whal man that’s an offer that’s hard to refuse but I’m in the uk so thanks for the offer. I’ll keep watching your videos though and find out if you’ve rebuilt an engine I own and use the info. Thank you 😎

[@timdonnelly8392]

I tore down my kx250 2003 ,I'm replacing all bearings in swingarm , linkage etc, the jug andl top end are brand new I'm a little weary about rebuilding the bottom end to have everything brand new, also changing graphics, handle bars clutch brake levers, disk guards installing a phat head from original adding a narly with a shorty full pipe and all new hoses lines and oversize radiators, this video made me a little more confident hope I don't mess it up😯

[@GregHitchko]

Right on Tim!! Let me know if you have any questions on the process. It's actually not as bad as you think, just take your time and double check things as you go along.

[@timdonnelly8392]

@@GregHitchko Awesome, I appreciate the offer, If I have any questions I will ask, probably won't get back on this project till spring, work as an Independent carpenter contractor steals all my time!

[@interstellaraxeman4468]

This is GREAT video for any KX owner....

[@GregHitchko]

Really appreciate that man! Looking to share the knowledge and little entertainment 👍

[@mikebowen4342]

Greg, excellent video instruction. My sons and I just got through rebuilding a 2004 KX 250. This bottom end video was the best, I must have watched it a dozen times before I put the bottom end together. We had a good time rebuilding it together. I watched all the videos on the KX 250, great resource. Thanks for taking the time to teach.

[@GregHitchko]

This is amazing Mike! I am so stoked that you two were able to find value in the video AND spend a rad time together rebuilding the bottom end. Exactly why I create videos to be able to help out in situations like this. Now finish up that bike, and go rip it!

[@aussiedigger1441]

Thank you so much for this fantastic video. The 1 task i wasn't looking forward to was the gear cluster and shift drum. Love your method with gears and I will be definitely using the same. I already feel more confident. Thank you👍

[@GregHitchko]

This makes me so pumped for you my dude! So glad that you found the content valuable. I really tried to break it down for you guys with the gears and shift drum. Take you time and you'll nail it. Let me know if you have any questions during the process! Cheers

[@emfl4437]

I am totally enjoying your channel. I may have found a 1999 KX250 that needs a rebuild. If I buy it, it will all be thanks to you!

[@GregHitchko]

Right on dude! That is awesome to hear. I actually don't have this 2007 anymore because I picked up a 1999 KX250 myself. So I fully support that.

[@922polo]

It’s as easy as 123 lol. I’ve rebuilt one when I was 12 but ended up not needing a crank. Going in this week! Thanks for the tips

[@GregHitchko]

Yeahhh buddy! No doubt, it's really not that bad if you take your time!

[@marcelloroos766]

Everybody struggles with the frikkin' sirclips...❤

[@GregHitchko]

Wicked annoying eh!

[@fernandofernandez5719]

Can't believe 2 dislikes to this amazing video

[@GregHitchko]

Haha I appreciate you liking it my man!!

[@interstellaraxeman4468]

16:40 that Ah HAAaa! moment... Very cool.

[@GregHitchko]

Such a good feeling right?!? Haha Love it

[@19671967tc]

Thank you

[@GregHitchko]

No doubt man!

[@davidreynolds8341]

Anyway to make sure that you’ve done it right before top end installation

[@GregHitchko]

I apologize about the delay in the response here David. Couple things. 1 - You want to make sure that the crank rotates smoothly and doesn't get bound up anywhere during the rotation. If it does, it could mean that the main bearings might not be seated level or well enough, which would cause the crank to not be level and true when the cases go together. 2 - Make sure that you can shift through all of the gears. Put the shifter on, and rotate the crank while you shift through the gears. Go all the way up to 5th, and then back down to 1st, then back to neutral. You just need to make sure that it goes into each of the gears. 3 - You could also throw the kick starter on the kick shaft and push it down to make sure that everything rotates and that it returns back to it's home position. Hope that helps!

[@williamwilkinson434]

Greg, thanks for the video super helpful. I am currently rebuilding the same bike. Did you buy the bearing/ seals in a rebuild kit or all separately ? If you got it in a kit could you please provide a link I cant find a bottom end kit for a 2007 kx250. Thanks again .

[@GregHitchko]

Hey William! Sent you an email as well but for this build, I sourced all of the bearings and seals separately through Rocky Mountain ATV/MC! Check out wrench rabbit kits as well. Call All balls racing directly if you can't find a retailer that has one in stock!

[@Mechanimations]

Wish I would have watched the part about checking gear movement before I tried to assemble mine with a gear backwards. 😂

[@GregHitchko]

Haha I hear ya on that! I'm glad I had the manual to help teach me. I spent so much time reverse engineering it because I was terrified of messing something up.

[@mikevessey6930]

What process/system do you use when you are taking apart everything and trying to remember where everything goes? Do u label everything as you take it apart? I assume there are hundreds of part/nuts/bolts....I’d love to see a video of how someone labels everything or how they lay everything out when disassembling a bike. Is there a video out there? Thanks

[@GregHitchko]

Great question and can get super over whelming if you don't have a system to track everything! I use a combination of small plastic sandwich baggies that I label and my wife's Tupperware. Shhhh don't tell her though haha. I plan to produce a video of that and may have a trick up my sleeve on that topic in the near future.

[@mikevessey6930]

@@GregHitchko awesome thanks

[@rajelledragon5763]

Awesome 🤩

[@tylertellefson1429]

Hey man I have a question about my motor rebuild, is there any way I could get ahold of you for some help?

[@forkinforgin]

i need that shift drum do u by chance have part number all i come across is a 2 grove drum but you have a 3 grove one, thats my final peace

[@GregHitchko]

Hey Andy, I can help you with that. What year is your bike??

[@forkinforgin]

@@GregHitchko 95 case number kx250ke005464

[@forkinforgin]

the book i got shows the drum to be 3 grooves cause with the 2 grooves counter shaft shares fork with main shaft

[@GregHitchko]

@@forkinforgin I am seeing a 3 groove drum as well it looks like! Have you tried on Rocky Mountain ATV/MC's website? They have an OEM part finder and that where I looked it up! www.rockymountainatvmc.com/oem-schematic/5

[@vwgtdturbo]

great work!what do you think is a better engine what do you like more to ride, rm 250 2006 oder kx 250 2007?

[@GregHitchko]

I actually have never ridden the RM250 yet, but staying tuned on a comparison when I get these bikes back together!!

[@mikevessey6930]

Greg, I got one more stupid question 😀 How do you know what bolts get anti-seize and what ones get lock tight? Does the manuals tell you are is this something I should know? Thank you

[@GregHitchko]

Hey Mike! Great question. The manual definitely does a good job at telling you where to use Loctite vs antis-seize. The two main spots where you would want to use anti-seize are the engine pins/dowels so they don't get stuck in the case, and outside of the motor, you would use it on your chain adjuster bolts!

[@joaom3nd3s85]

How many nm you put in clutch hub? Great videos 😉

[@GregHitchko]

That clutch hub nut torque is 98Nm!

[@thepounders3670]

How did you get out that needle bearing for the shift drum? (The one you had to hammer in? Mine is so stuck in my case the puller wont do it. Awesome video

[@GregHitchko]

I hear ya! It requires a large puller for sure, super tightened down. You can try throwing the case in the oven face down, the bearing could fall out, or the extra heat could assist the puller!

[@thepounders3670]

@@GregHitchko this one is a piece of work haha, tried both oven and heat gun, maybe I need many light taps with the puller instead of smashing it like I did? :))

[@samfmx]

Is that outer water pump seal sits down flat side or face down?

[@GregHitchko]

It’s weird but the flatter side is down!

[@samfmx]

@@GregHitchko Thanks, Btw awesome and helpful vids!

[@GregHitchko]

@@samfmx not a problem my dude! Love being able to help out. Let me know if you have any other questions as well.

[@samfmx]

@@GregHitchko yes! Now that first gear of the main shaft popped out like yours, which way goes back in shaft? Theres like a small groove on the other side

[@Kiefyblunt]

I need some help on where those 2 o rings go on the counter shaft! Do they just sit on the counter shaft??

[@GregHitchko]

Yup! Just slide them right onto the countershaft and they just kind of chill there when you put the collar on.

[@Kiefyblunt]

Appreciate it awesome vid!

[@michaelhernandez8102]

Hey why aren’t my cases going back together? It’s not the dowels and the crank is seated fully

[@GregHitchko]

Where is it getting stuck or bound up does it seem? Is the transmission stopping it somewhere?

[@maxhuggins7625]

Would this be pretty much the same for a 07 kx 125??

[@GregHitchko]

The process between any of these two strokes is actually super similar!

[@hydro42060]

Hot rod bearings how are they holding up?

[@GregHitchko]

They are actually all OEM!

[@hydro42060]

@@GregHitchko what model can't find a kit for a 94 anywhere or will I have to make a order on the Kawasaki site

[@GregHitchko]

@@hydro42060 I pieced all of the bearings together from Rocky Mountain's OEM website, there wasn't actually a kit

[@GregHitchko]

@@hydro42060 it actually wasn't a kit. I bought all of them individually from their OEM parts finder website!

[@jordanearl6162]

Hey I have a question for you

[@GregHitchko]

Hey Jordan, sure, what's your question man?

[@mse_playz7968]

Hey Greg I have a question for you

[@GregHitchko]

Yeah man what's your question??

[@mse_playz7968]

@@GregHitchko Hello so my 2001 kx 250 when I got it it was locked up I took the top end off and got some of the metal out and everything then it came unlocked so would I need just a top end or bottom too?

[@GregHitchko]

@@mse_playz7968 I would definitely split the cases on the bottom end too to confirm that there are no small chunks of metal down there! If the crank has up and down play in it, you will have to send it out to be rebuilt with new bearings of just get a new crank as well. But that is what I would for sure do!

[@mse_playz7968]

@@GregHitchko thanks yea I wanna send it out but a shop cost like 1300 to rebuild just the bottom end iv really never done it before

[@GregHitchko]

@@mse_playz7968 I can see that being the case with labor and parts. A crank rebuild from Millennium Technologies will be about $225, bearings will be around another $100, tools to complete the job will be about another $100, then a bottom end gasket kit or complete gasket kit will be $50-70. So it'll be a little over $500 probably to do it yourself, i'd say. Grab a manual and follow along with the videos and ask me any questions if you go that route!

[@davidreynolds8341]

Anyway to make sure that you’ve done it right before top end installation