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      HOW TO: 4-STROKE PISTON REPLACEMENT DONE RIGHT!

KX250FJP

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About KX250FJP

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    Mississippi
  1. http://www.rockymountainatv.com/productDetail.do?&navType=type&webTypeId=203&navTitle=Engine&webCatId=17&prodFamilyId=6069#vehicleSelect Rocky Mountain sells the Steahly.
  2. Worn rings can allow pressure to buildup in the crankcase and push oil out of the overflow. How many hours do you have since the rebuild?
  3. The link most of us used is no longer working. I can email you a copy if you would like.
  4. •Install the cylinder head. ○The camshaft caps are machined with the cylinder head; therefore, if a new cylinder head is installed, use the caps that are supplied with the new head. This is quoted from the service manual. If you notice on the parts diagram in the post above, it does not give a part number for the cam caps. They are sold and machined with the cylinder head.
  5. http://www.kawasaki.com/Home/Home.aspx If you go Kawasaki's web sight at the above link, under owner info, parts diagram the part number for the '09 piston is 13001-0088. Motosport.com lists the '08 piston as 13001-0088 and has it in stock. I think DK had it right, the '08 and '09 pistons are the same.
  6. What torque did you use on the cam caps?
  7. The '08 cylinder head is a part number 11008-0116, the same as the '07. It should bolt up with no problem. I have the '07 head on my '05. I used the '05 Wiseco piston with the '07 head and have 34 hours on it with no problems.
  8. The o-rings (A) go on the shaft, then the spacer (B)slides on and the groove © seats on the o-ring.
  9. I have an '05 KX250F and I used the '07 parts that have the plate in front of the plug so it can't blow out. Part number 92066 in the picture (Kawasaki # 92066-024) is the plug and 13271 (Kawasaki # 13271-0675) for the plate to hold the plug and 132 (Kawasaki # 132L0612) if you lost the screw.
  10. Take the sprocket off, behind the sprocket is a spacer and there are two o-rings behind the spacer. Those are usually what cause the leak.
  11. Valves run about $40.00 per valve for the SS. The springs from Kibblewhite for the SS valves run about $200.00. Seats cut for about $75.00.
  12. That hole is where an accessory manual decompression device would go. They have a plug part number 92066-0024 on the '04 that was held in by a bolt part number 92153-0806. I have an '05 and I bought the plug and used the plate from an '07 to hold the plug in, part number 13271-0675 (only $1.81 on motosport.com). The screw for the plate is a number 132L0612. Much better system, will not let the plug blow out.
  13. That is unusual for the intake to get loose. The Stock Kawasaki shims come in increments of .025 mm. So if you are at .33mm and want to get to .15mm you would need to go about 8 sizes larger than what is in there now. The exhaust you would go down 2 sizes to get into spec. Like I said it is very unusual for the intakes to get that loose. I would check your measurements
  14. The part number is 92151-1423 for the bolt. The oil filter cover is pictured with the water pump in the parts catalog.