Maintenance & Technical > KX250 / KX125

Interchangable parts?

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ihampson:
Hi, I am a bit confused about which parts are interchangeable.

I am trying to rebuild a 87 250 but am struggling to find good used spares. The r/h crankcase is cracked and the water chamber on the barrel is smashed. I have been told that the crankcases from newer engines (up to 92) will be ok with the 87 internals as there are only slight differences. but the dealers say that each year has a specific set, and the clymer manual has diagrams for 82-86, 87 and 88-91. In the manual some other internals stay the same (shift forks 83-91, shift mechanism 85-91 + kx125 85-91) exhaust advancer assy 87-91, clutch 87-91, primary drive gear 87-91, gear shift 84+) but there is two different gear assy (82-87 and 88-91) How accurate are these diagrams? Are they generic and only show the layout is the same but the parts may have different dimensions? Also the gear assy apears to be completely different. Is the way they fit into the case the same? maybe with different bearings?
I have found a mitaka conrod kit that claims to fit all years of kx, has anybody else used one? did you have to order a specific kit for your year bike? if one size fits all would it be a fair assumption to say the crank is the same?

Sorry for all the questions but i`m new to kx`s and this has got me beat. any advise or suggestions would be greatly appreciated.

KZ-Rob:
The Kawasaki web site has parts diagrams with numbers, unfortunatly its by model years, not by interchange. Look up the parts in question, if the part numbers are different, chances are they wont work. Kawasaki loves using the same parts as long as possible, sometimes for 30 years if they can.

CR480R:
I dont know much about the transmissions.. But I do know that the cylinder and crank will definately work in the newer cases...

ihampson:
Hi guys, thanks for the replies. cr480 i have been reading your other post about rebuilding you kdx engine and it was very interesting. I had previously been told that the kx and kdx shared the same bottom end but using a different top end, and a flywheel weight on the kdx to help bottom end power. I was a bit dubious, thought it might be another urban legend. From the sounds of it your rebuild is going well and would love to hear your progress, was everything straight forward or did it take a bit of modification other than the power valve rod?
Good to see there are some actual mechanics about rather than just fitters, which is the case at my local dealers.
Keep up the good work!

i have decided to buy the con rod kit after the holidays and hopefully it will fit. I also have a top end from a 89 bike which is NEARLY the same to mount as the `87. it fits the crank case, inlet, exhaust etc,  exactly the same, the only thing difference is a idler gear for the powervalve, there is no recess on the case for the stub to fit into. Hopefully i can use a newer crank case so this wont be a problem, alternatively i will have to machine a small hole in the case so that it will bolt down all of the way. sounds extreme but looks quite straight forward. Time will tell i suppose. will keep you posted.
It would be good to create a list of interchangeable parts. maybe we should start a new post and we could update it as we go along? could save us all some money and hassle. And make it easier to find used spares from breakers, ebay etc. What do you think?

CR480R:
My engine besides the powervalve lever and 2 cylinder studs(wrong length) was a direct bolt together deal... I had an '88 cylinder I was going to use before I bought the '98 and it fit the '91 cases just the same... I wouldnt be surprised if your internals will fit in the newer cases just fine, but I would buy a complete bottom end just to be sure... even if you have to swap in your good crank to make it a runner at least you'll know that the trans is right.

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