How do i rebuild a 99 kx250 engine - 2006 kawasaki KX 250

adjust the clutch cable to take up that clearance
have you fitted all of the clutch plates correctly in the clutch pack

1989 Kawasaki KX250 Repair Manual Download
This Manual Covers The Following Machines:

1988 Kawasaki KX125 2-Stroke Motorcycles
1988 Kawasaki KX250 2-Stroke Motorcycles
1988 Kawasaki KX500 2-Stroke Motorcycles
1989 Kawasaki KX125 2-Stroke Motorcycles
1989 Kawasaki KX250 2-Stroke Motorcycles
1989 Kawasaki KX500 2-Stroke Motorcycles
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Yes you will have to split the engine and more than likely have to replace the 5th gear shift fork. It can be a common fault with this model kawasaki. New old stock part is not available so you will need to locate a good second hand one.

What the mechanic is talking about is the degree of the camshaft gear to the crankshaft. The easiest way to do this is with a degree wheel, but the timing degree should not have changed during rebuild and is pretty hairy to change manually. The marks on the flywheel are degree marks, and there should be 1 timing mark. You will have to find out from a kawasaki dealer which mark to use for correct timing. Hope this is what you were needing, Daniel.

Try a .162 main jet,48 power jet,carb on 3 or 4th clip to the main jet.
Some boyser power reeds might help also about atotal of 60 to 75 bucks for the whole deal and that should get you to bonzai state in no time.

If you need to replace a crankshaft for a 99 Honda Civic EX, it may mean that there's more damage to the engine than is worth inputting financially for that service.

Is the engine knocking severely indicating a bad main bearing? If so, a replacement used engine may be more economical than rebuilding the one you have.

Good luck on this repair.

A car that old is not worth rebuilding the engine. For the price of an engine rebuild you can buy a 99 Saturn with half the miles. Or you can call a junkyard and see if they can locate you a SOHC saturn engine to fit a 92, probably any Saturn SOHC up to 95 will do. Used motor will cost 300-400 dollars plus removal/install while a rebuild will cost you 1500 at least plus a removal/install.

Hello. Get a can of starter fluid and a helper. Have the helper squirt some starter fluid into the air intake area while u start it. then use starter fluid to keep it running until it runs on its own. If this does not do it, you will probably have to rebuild the carburator. Joe

there are a handfull of secrets to rebuild one of these. An ATSG rebuilding manual will give you nearly everything you need. The secrets usually aren't in the books though.

G,Day back.Not sure about how much oil to put in the forks but may be able to help you stop the leak.Get a film negitave from a camera.Like the ones that come in the developed packet.Cut the notched section off the side of it.Trim one end at 45%.Now slide this into the fork seal and with a sawing action,move it all the way around the seal.When you get the feel of it,you will be able to feel bits of dirt in the seal.When you do,pull it out and the dirt will come with it.Do this a few times.This will work if the seal are not cactus and is cheaper than a rebuild.Hope this is of some help.