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View Full Version : KX250 Cylinder removal???


trailrider894
02-23-2011, 09:17 AM
Hey guys, i am stuck.... I can not figure out how to disconnect the governor shaft and rod from each other to get the head off... I have never even touched a kx250 until this and i need help!! If any has a step by step i would greatly appreciate it.... Or a link to a service manual download.
krt400ex
02-23-2011, 10:14 AM
what year is it? i dont honestly know the terms, but i'm assuming you are talking about the little rod on the right side behind the exhust pipe that works in conjunction with the powervalve? i rebuilt my buddies 99 kx250 and if i remember correctly i think there was like a little cotter pin i had to pull apart. that was two long years ago though
trailrider894
02-23-2011, 10:16 AM
Originally posted by krt400ex
what year is it? i dont honestly know the terms, but i'm assuming you are talking about the little rod on the right side behind the exhust pipe that works in conjunction with the powervalve? i rebuilt my buddies 99 kx250 and if i remember correctly i think there was like a little cotter pin i had to pull apart. that was two long years ago though

Yeah man... i thing it is a '00 or '01. That is exactly what i am talking about!!!!!!!!!!!!!
krt400ex
02-23-2011, 10:39 AM
i'm pretty sure there was a little cotter pin with a washer on it. i'll look up a diagram. did you pull the cover off? because behind that little cover is where you'll be taking it apart
trailrider894
02-23-2011, 10:46 AM
Originally posted by krt400ex
i'm pretty sure there was a little cotter pin with a washer on it. i'll look up a diagram. did you pull the cover off? because behind that little cover is where you'll be taking it apart

The rubber cover??
krt400ex
02-23-2011, 11:00 AM
this should be a link to a diagram i found.

http://www.bikebandit.com/houseofmotorcycles/2000-kawasaki-kx250-kx250l2-us/o/m3844#sch60996

i'm having trouble remembering, but i belive the two circlips (482) need to be removed and i believe there should be a rod or something attached to number 49046. my memory is vague. i tried to find a diagram of the other side of the engine but came up empty handed if you could put a picture up so i can see it again it might be helpful
krt400ex
02-23-2011, 11:01 AM
Originally posted by trailrider894
The rubber cover??

there is a plastic cover and a rubber boot. both need to come off to access the linkage that you need to take apart. its on the right side. behind where the expansion chamber of the exhaust pipe sits
trailrider894
02-26-2011, 03:23 PM
Got the cylinder off.... it revealed the infamous shattered piston... Well, not sure what to do next....
trailrider894
02-26-2011, 03:32 PM
How do i clean out the crankcase with all those parts down in there??? Or do i have to split the cases and go from there?
450Rida
02-26-2011, 03:47 PM
your gonna hav to split the cases and clean. and check all the bearings
trailrider894
02-26-2011, 04:06 PM
Originally posted by 450Rida
your gonna hav to split the cases and clean. and check all the bearings

Will do... Is splitting the case easy?? Or do i need to buy a special tool?
CJM
02-26-2011, 07:37 PM
Originally posted by trailrider894
Will do... Is splitting the case easy?? Or do i need to buy a special tool?

maybe a flywheel puller, but I doubt much else.