Trans question KX250

[shookyd]

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.

[sandblaster]

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

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...

[shookyd]

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.

[motopunk]

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.

[shookyd]

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?

[shookyd]

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

[motopunk]

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.

[shookyd]

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.

[shookyd]

Would also like to use the 2001 cylinder because it was just replatted.

[motopunk]

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 . 

[shookyd]

Are the stators interchangaeable?

[shookyd]

What are the electrical wires going to carb on the 2001?

[motopunk]

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 .

[motopunk]

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. 

[sandblaster]

Thanks motopunk!
If anyone needs any parts from me DO NOT buy them from eBay, just shoot me a PM for direct pricing