Maintenance & Technical > KX250 / KX125

96 KX250 splitting cases

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Tonybeau:
I'm going to order parts soon to do this.

Another couple of questions though.  I noticed when doing the top end that a previous owner installed a hot rods crank.  Reading this thread http://www.kxriders.com/forums/index.php/topic,15287.0.html it looks like the general opinion on these isn't good.  Do you think I should remove this and replace with OEM as don't really want to be tearing the engine down again too soon?

Also would a 98 OEM crank be ok in a 96 engine?  I know the part numbers differ slightly but I read that Kawasaki increased the crank weight to smooth out the bottom end (which I would prefer anyway) and I have also found new 98 cranks for around 30% less than the cost of the 96.

sandblaster:
I would rebuild your crank using a Wossner rod kit.
Next OEM
Next Pro-X
The rods are the same for many years.
I believe 92-04 cranks will fit but ask Doldguy as he is a 250 guru...

SOHC:
When you install a hellicoil into a kx it blocks off the small hole that lets the oil drain out of the bottom part of the case under the clutch

Tonybeau:

--- Quote from: sandblaster on September 06, 2015, 05:29:07 PM ---I would rebuild your crank using a Wossner rod kit.
Next OEM
Next Pro-X
The rods are the same for many years.
I believe 92-04 cranks will fit but ask Doldguy as he is a 250 guru...

--- End quote ---

Thanks, I'll check into it.


--- Quote from: SOHC on September 06, 2015, 05:47:05 PM ---When you install a hellicoil into a kx it blocks off the small hole that lets the oil drain out of the bottom part of the case under the clutch   

--- End quote ---

That doesn't sound good. Will this cause a running issue or just mean that when the oil is drained it won't drain everything.  Is there a better alternative that doesn't involve replacing the cases?

Foxx4Beaver:

--- Quote from: Tonybeau on September 06, 2015, 06:32:58 PM ---That doesn't sound good. Will this cause a running issue or just mean that when the oil is drained it won't drain everything.  Is there a better alternative that doesn't involve replacing the cases?

--- End quote ---

I installed a Helicoil in a '97 KX250's oil drain several years ago...very simple job, about 15mins. 
All you have to do is measure the depth, if I remember correctly, 10mm was good...then you want call Helicoil and order an M10 x 1.25 x 10mm stainless steel helicoil, and get a small bottle of Loctite 266, you'll be putting that on the outer threads of the helicoil just before you screw it into the case, then it will never move.

Time-Serts are another good way to go...but since the drain plug is such a low torque bolt, it's a bit overkill, and quite a bit more money.
I ran my '97 for 4 years with the helicoil...sold it to a buddy, who rode it for another 5 years without any issues. The key is to remember not to crank down on the bolt, just snug it up and safety wire it.

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