KX250 1999evo...strange fuel leak etc.

[GRARA]

Ah thanks ...kind of pricey,i will check on internet for anything in the U.K, also what am i better off replacing while the engine is split?
Full new gaskets,oil seals,pos.new piston kit....
is there anything else that needs replaced?

Thanks again.

[Foxx4Beaver]

you probably don't want to hear it...but at the very least, you want to replace every bearing, every seal, every snap ring...thoroughly inspect every gear/fork/shaft/shift drum in the tranny for wear, and replace anything that looks questionable.
thoroughly inspect the clutch hub, basket, pressure plate, fiber and metal plates.
get a complete Cometic gasket set...
http://www.cometic.com/

go with a Wossner piston...
http://www.wossnerpistons.com/products/mode/filter/search/Kawasaki?fitment-category-id=BBB40D59-0BEE-E011-963B-000C29296656&fitment-category-name=2+Off-road

I replaced the entire tranny/bottom end in my 500 last year, because I plan on keeping it for a long time...if you plan on keeping yours for awhile, I'd replace as much as you can as well.

yeah that particular puller is pricey, but it's good, just shop around, e-bay has them too...you could always rent a puller/case splitter if you don't want to buy one also.

[GRARA]

WOW ........need to do some serious overtime!!
Ive already ordered a new piston kit,full gasket kit,oil seal kit and a full bearing kit from ebay...probably not the best kit in the world but im sure (hopefully) it will do my injured ride some good.
Ive managed to get some help from a friend of a friend,who is a bike mechanic and he is going to show me how to do all this step by step,and if it needs other new parts on the way he will advise.


Thanks again for the much needed advice.

[Foxx4Beaver]

well at least you're replacing the bearings and seals, hopefully they're good quality...but definitely get new snap rings for the tranny....there's nothing worse than doing a rebuild, and then having a snap ring break just hours after the "break-in" period...then you have to tear it all back down and start over again.

[GRARA]

Snap rings??  this probably sounds stupid.... but how many do i need?

[Foxx4Beaver]

part numbers.....

snap ring 25mm...92033-1089...there are 4 of these
snap ring 18mm...92033-029...only one of these
snap ring 24mm...92033-026...only one of these....this is the front sprocket snap ring.

about $30 to your door should cover it through Rocky Mountain....or who ever you decide to use.

[GRARA]

Thanks Foxx4Beaver you really know your stuff

[Foxx4Beaver]

Thanks Foxx4Beaver you really know your stuff

being old helps

[GRARA]

Ok here goes...after tear down all parts seem to be quite new...but replacing seals and bearings anyway,looks like the piston rings were shot (just shows you that when the rings LOOK ok they prob.arent)causing fuel to seep down into the crank and eating through the casing sealant.The casing has a soft spot where the previous owner had used a screw driver to separate the casings and damaged the edges,then filled the damaged area with sealant,and the fuel which was going past my rings found a way out!!!
So,getting my damaged area re-welded and sanded down before we seal engine together again.
The inlet rubber from carb to engine was also burst causing engine to take in air..!!

Annnnnd another problem...the teeth on the drum valve (power valve)have sheered ,this is why my power valve has never worked...
Does anyone know if Kawaski Part no 12005-1182 will fit onto 98/99 KX250 they look identical.....Foxx4Beaver needing your help here?

Lesson learned here people.....I checked rings --they LOOKED fine,i checked the carb so many times,but over looked the inlet rubber,even after i had removed the reeds at least 5 times!!!!

[Foxx4Beaver]

what year bike is the 12005-1182 supposed to be for?

I have the 99's listed as...
Left...12005-1284
Right...12005-1285

[bens87braap]

12005-1182 VALVE-EXHAUST is the left 93 94 says only fits 93 94

[GRARA]

I found this on ebay....Kawaski Part no 12005-1182 is 93/94 but looks exactly the same ......
To buy a dirty second hand power valve assembly in Scotland its going to cost me £100 ,but all i need is the one drum valve,im not cutting corners here and im  not paying for something i dont need.Im sure u would agree.


Thanks for the RAPID response guys!!

[bens87braap]

well I just incounted the same problem with my 87 250.  i sheared one of the gears on one valve but had to buy a complete set second hand so now I got some spare bits lol     

If the valves were the same I would think that Kawie would keep same part number but only one way to no for sure someone here may no more I just searched for the answer for you 

[GRARA]

Well bens87braap i might just do the same,that way i will also have some spares
Were your valves all carboned up also?

[bens87braap]

my left valve was destroyed on inspection my bike was allways like that now im not running any power valves lol

This is what I pulled out of the motor