1994 KX250 Rebuild Part 3 (Cylinder Honing, Testing Gears, Finding the Culprit of the Breakdown)

In part 3 of the 1994 KX250 rebuild, we focus on assembling the left and right case sides. We also found the likely culprit for why the bike was stuck in 4th gear, a shredded shift spring. Lastly we honed the cylinder on this bike. Stay tuned for part 4!
For business inquiries direct message @mppowersports on Instagram.

[@christopher-michaelcopolil4062]

Perfect timing, I just got done with my bottom end bearings and seals on my 94 kx250, waiting for the new crank and cylinder to come back from Power Seal! Thanks for posting these!!!!

[@ridgedavis9803]

Can’t wait until the kx250 is up and running

[@easymoneytots]

fireeeeeeeee, they do such high quality work

[@garageuniversity]

That's a good-looking shop. Thanks for sharing.

[@frejsi6612]

where can i get ball honer, and also where did you get your new piston?

[@ryleyverbeek44]

Being that this KX is almost 30 years old I fear that the Nikasil coating is probably gone. Both my ‘90 and ‘93 250s were completely worn out. The replete was $500 😳

[@93paxon]

who did you get yours done through?

[@ryleyverbeek44]

PowerSeal USA

[@nicolasbellemare8958]

I sold my kx250 to my friend and he said the rear wheel locked up. I took it back and disasembled the transmission but couldnt find anything. The guy put a 15t front sprocket and i found rubbing marks on the casing behing the sprocket. Would you say its something possible because everything looks fine no loose bearing or missing tooth... im about to put the engine back in the frame but im kind of scared of what will happen 😂

[@keshmo12]

Good build so far. Did the kx250 have no nikasol coating on it? My cr250 had nikasol coating and if you honed it like that it ruins the coating. Basically all you gotta do is use scotch brite and knock off the glaze.

[@MPPOWERSPORTS]

Yes with nikasil coated cylinders you have to be careful not to chip the coating on the edges of the ports, this particular cylinder is not so we didn’t have to worry about that. Still pay close attention to the cylinder coating and condition when honing/deglazing!
We will post an in-depth video explain different honing/deglazing techniques for different types of cylinders! Hope this helps

[@christopher-michaelcopolil4062]

@@MPPOWERSPORTS on mine I got it for like $200 and a ring had caught on a port so it had a good 1/4” gash straight down through to the aluminum. 2 grand later and this things gonna be brand new!

[@dennisgriffith3741]

Just did a ball hone on my 95 kx 250 worked like a charm. I heard conflicting arguments but I have the before and after picks and let me tell you the performance on this kx is amazing