KX Riders
Maintenance & Technical => KX250 / KX125 => Topic started by: shookyd on April 04, 2013, 11:11:47 AM
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Will the transmission from a 2001 KX250 work in a 1992 motor or will the cases for a 1992 work for a 2001? Please help.
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Hello shookyd.
Welcome to the site.
Not according to Kawasaki Interchange info.
You can look up a bunch of that info here:
http://www.oem-cycle.com/KAWASAKIKX250BIKEID.shtml (http://www.oem-cycle.com/KAWASAKIKX250BIKEID.shtml)
You will need to scroll down and way to the right :-)
That being said, just because a part number is different does not mean that the parts won't interchange but you can rest assured that something is different.
I hope someone here has actually tried it in the past and can let you know...
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thank you for the info. If anyone else knows, please respond, great link too. I found a 2001 that I can get for about nothing and I already have the 1992 parts bike with complete engine that has a bad tranny. Just looking for a way to bring life back to the green machine. great site here.
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hello... :-) the cases will fit from 92-2004 to the transmission, but there some little differences. the kx250 92 to 96 cases are the same,
in 97 kawasaki took some little changes . another shift forks with bigger pins .which means you could in 92 case only use shift forks and pins 92-96 and in the 2001 case only the forks and pins 97-2004
in the 97 to 2004 cases is a bolt-less on the clutch cover, which means for example that the 2001 clutch cover not fit to 92 cases...
the kx250 transmission gears and shafts are the same 92- 2004 . since 99 is a finer toothing for the sprocket on the transmission output shaft.
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Great post motopunk!!! Looks like I may be in business, Two more questions, is the top end compatible with the bottom end between the two years? Will this rebuild kit work for the 1992?
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Oops, forgot to post the link to the rebuild kit.
http://www.ebay.com/itm/Wiseco-Top-Bottom-End-Kawasaki-1993-2001-KX-250-Engine-Rebuild-Kit-Crankshaft/151008469495?_trksid=p2045573.m2042&_trkparms=aid%3D111000%26algo%3DREC.CURRENT%26ao%3D1%26asc%3D27%26meid%3D6745950278546809595%26pid%3D100033%26prg%3D1011%26rk%3D3%26sd%3D130842407984%26#ht_2766wt_674
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im not sure. i dont know which bore and stroke is in the ´92 .
93-2004 is 66,4mm bore and 72mm stroke .
but you can measure it out. take off the sparkplug and stator cover.
Take a thin rod, put it in the spark plug hole until you're on the piston. then turn the flywheel until the piston is at the bottom. Carry an accurate mark at the rod. then turn the flywheel until the piston is at the top. take again an exact mark on the rod.
at least measure the distance between the marks. and you have exactly the stroke of this '92 engine.
if there are 72mm the "Wiseco Top & Bottom End Kawasaki 1993-2001 KX 250 Engine Rebuild Kit Crankshaft" maybe could fit . (feel free and take a call to this seller )
I think the rebuild with the newer kx-motor will be better and easier.Take all the needed parts that match to the 2001 out off the 92.
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The 1992 is 66 bore and 72 stroke. Here is what I have, 1992 with bad tranny, 2001 with rod thru the front cases which makes them unuseable. I would like to do full rebuild on the 1992 and put in the 2001 tranny. I would also like to use the 2001 stator because it has the nice electrical plugs that plug right in to the wiring harness. Is this doable? Another difference I see is the carb has two plugs off the wiring harness going to it. What are these for? I have not had a bike with electrical wires going to the carb before. Thanks for all the help. This bike is gonna be sweet.
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Would also like to use the 2001 cylinder because it was just replatted.
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The 1992 is 66 bore and 72 stroke. Here is what I have, 1992 with bad tranny, 2001 with rod thru the front cases which makes them unuseable. I would like to do full rebuild on the 1992 and put in the 2001 tranny. I would also like to use the 2001 stator because it has the nice electrical plugs that plug right in to the wiring harness. Is this doable? Another difference I see is the carb has two plugs off the wiring harness going to it. What are these for? I have not had a bike with electrical wires going to the carb before. Thanks for all the help. This bike is gonna be sweet.
ok... :-) what you still have to watch out is the shift forks of the 92 cases all are in good condition.
the 2001 cylinder has the better exhaust valve and 5 hp more than the 92 cylinder . :-D
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Are the stators interchangaeable?
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What are the electrical wires going to carb on the 2001?
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no... this are different ignition systems. you cant interchange nothing. the 2001 ignition system is with a slide sensor and powerjet in the carb . this was real evolution in 99 as this system came first in the kx250´s .
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take a look at this...
http://www.kxriders.com/forums/index.php/topic,11418.0.html
sandblaster has a 99 kx250 case for sale. it is the same like your 2001 cases. this will eliminate your problem perfectly. :-)
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Thanks motopunk!
If anyone needs any parts from me DO NOT buy them from eBay, just shoot me a PM for direct pricing :-D
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Thanks motopunk!
If anyone needs any parts from me DO NOT buy them from eBay, just shoot me a PM for direct pricing :-D
:-D thats good to know... you are great sandblaster :-D
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I got the 2001(cracked cases) apart and down to splitting the cases on the 1992, It appears to me that the stator off of the 2001 should work in the 1992 as long as I use the same flywheel. Biggest issue I see now is diagnosing the problem with the 1992 tranny, but at worst case, I am thinking its the shifter forks which Motopunk has stated wont interchange, might have to buy a set of shifter forks on ebay, Sandblaster, do you have a set of 1992 KX250 shifter forks?
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PM sent :-D
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I got the 2001(cracked cases) apart and down to splitting the cases on the 1992, It appears to me that the stator off of the 2001 should work in the 1992 as long as I use the same flywheel. Biggest issue I see now is diagnosing the problem with the 1992 tranny, but at worst case, I am thinking its the shifter forks which Motopunk has stated wont interchange, might have to buy a set of shifter forks on ebay, Sandblaster, do you have a set of 1992 KX250 shifter forks?
shookyd, you´re on a right way, but you can also buy a set of cheap cases for the ´01 motor (97-2004 will work ) i think that might be easier 8-)
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Just sent my cylinder off to be replated and piston fit to it, ordered bottom end kit and topend gasket kit from ebay. I know this is probably a stupid question but I have never rebuilt an engine. Do the bottom end kits come with the rod already on the crank or is that something I have to install and figure out clearance for the rod bearing?
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Just sent my cylinder off to be replated and piston fit to it, ordered bottom end kit and topend gasket kit from ebay. I know this is probably a stupid question but I have never rebuilt an engine. Do the bottom end kits come with the rod already on the crank or is that something I have to install and figure out clearance for the rod bearing?
no... this aftermarket-kit comes ready to build in... i have never seen aftermarket cranks that were sold apart. 8-)
would like to see a pic of your blown cases where the rod hangs out... an which parts of the 92 tranny are damaged? i think you could bring both motors back to life sooner or later... having a backup motor is always a good thing.. :-)
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thanks Motopunk...gotta learn by asking questions. Just glad there is helpful knowledge on this site that is willing to share.
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take questions is always better than making fails... :mrgreen:
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Time for an update. I got my cases back together. Still waiting on my cylinder to come back. I used the entire transmission out of the 2001, including the shifter forks and rods. I had the 2001 shifter rods machined down to the diameter of the 1992 shifter rods 10.5mm back on the ends so they would fit the 1992 case which also allowed me to use the 2001 shifter forks. I also had to change the bearing for the output shaft because the 2001 was slightly larger. Bad news was the gear set lever was very worn and broke when I reinstalled it, got a new one on the way. Can't wait to crank the throttle on this one.