Question about 2003 kawasaki KX 125

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How much will it be to get my cylinder re sleeved for a kx 125 20003

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Its cost differently in other areas but you can be looking around $400 or better.

Posted on Nov 19, 2009

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Engine rebuild

Bummer. Usually you need to drop the oil pan, pull the rod and piston out, replace the sleeve, and use a ring comprssor to get the piston back into the cylinder and then put it all back together EXACTLY how it came apart including position on the sleeves, rods and bearings. I have not done this on a VW but I do not see this being much different than any other car that I have worked on. No matter what it will be a huge pain in the ***.

Jun 06, 2013 | Volkswagen Cars & Trucks

1 Answer

How to bore out top end of motor? and how much does it cost?

Honestly - it's just as cost effective to just buy a new cylinder complete from Yamaha - unless you have a lot of porting done to your cylinder. The cylinders are plated and you typically don't bore them - you have them re-sleeved.

I have raced semi-pro for many, many years (AMA District 13, A-class). When I raced 125s (1998-2002) I would usually go through 6 to 8 cylinders per season and I would rebuild the engine after every race (every week). I never bothered getting the worn cylinders resleeved because the sleeves cost almost as much as a new cylinder from Yamaha.

Price out a new cylinder then price out the re-sleeve. You'll see there's only a slight difference. I recall the new cylinders being about $245 and a sleeve was around $225.

Once you get it rebuilt, keep the ring fresh and make sure you run at least 28:1 mix. I raced at 26:1 to get the engines to last. They are single ringers and the piston ring just doesn't last. Yamaha recommends changing the ring every 2.2 hours for maximum output. I couldn't get 2 hours on a motor running 32:1, so I switched to 26:1 for more lubrication and better sealing of the ring. Long story.

I hope this helped.

Sep 30, 2011 | 2003 Yamaha YZ 125

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A piece of metal scrathed the side wall of my piston sleeve and goudged the top of the inside of my crankcase,like where my spark plug scews siezed up and when i opened it i noticed antifreeze on top...

There should be no play up and down. Any play is coming from a worn out needle bearing on the crank. A bit side to side is okay and normal. The crank will need to come out then it gets pressed apart and fitted with a new bearing. Price out the difference in cost of fixing the crank verses getting a new $170 crank assembly.What probably happened is a broken piston ring extended into a cylinder port and the piston against the ring is what gouged the cylinder and head. Please rate my answer.

May 29, 2011 | kawasaki 125 Dakar Motorcycles

1 Answer

Can a kx250 2002 two stroke barrel be rebored or should the sleeve be replaced .

Replace the sleeve is the only option - I think there would not be enough cylinder wall left if you rebored it as it is a sleeved cylinder it relys on the sleeve for extra wall thickness and strength you can rehone the sleeve if it is not too badly scratched you can get honing tools around $80 ish? they fit into cordless drill

May 26, 2011 | kawasaki KX 250 Motorcycles

1 Answer

I need to sleeve the cylinder on a 1984 yz 125 and I want to know if I could use a sleeve for a newer yz 125. Like say a 1987 or 88.

Contact they can provide you with the sleeve you need, or bore and hone your existing sleeve.

Jan 15, 2011 | 2003 Yamaha YZ 125

1 Answer

Is there a coating on cylinder of my 01 kx 250 that wears off to make the cylinder usless

Yes, that is a plated cylinder so if it galls, or wears out, it cannot be bored out you have to put a new sleeve in it. The new sleeve will be able to be bored out so it will last for a long time. The resleeving is best left to a cycle shop or machine shop with the propper equipment, as it is an interfearence fit and the cylinder must be bored perfectly, then heated in an oven to be able to install the new sleeve.

Apr 18, 2010 | kawasaki KX 250 Motorcycles

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Can you bore a sleeved cylinder from a standard 1991 Kawasaki kx 250 or will it need to be re-sleeved? Not sure if the cylinder sleeve is stock. My understanding is that Kawasaki installed factory sleeves...

If you say it is definately sleeved it should be possible to bore it, you normally get one or two oversizes before it needs resleeving. If you are able to buy an over size piston from kawa or wiseco, chances are it can be bored.

Apr 16, 2010 | 2003 kawasaki KX 250

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I have a 01 kaw bayou just put a top end kit in now i have piston slap please help even bought a sleeve for it had some yaho pressed @ bored it not sure if he did it right bore diam is 66.8

if it is piston slap,you will need pull the top off again and measure with a feeler gauge between the piston skirt and the sleeve, should only be a couple of thou

Mar 21, 2010 | 2003 kawasaki KX 250

1 Answer

I blew the engine from bad gas and pre-ignition/broken piston. LA sleeve did the cast sleeve and a wiseco piston with .003 clearance. Engine is noisey so I took it back apart. Very slight lower rod brg...

yes buddy thats the big end bearing im afraid if its moving up and down a slight bit its and engine rebuild it will move side to side buddy get back to me buddy

Nov 09, 2009 | 2002 kawasaki KX 500

1 Answer

Cylinder 1991 kx 125

If your going to the trouble of replacing the cylinder - wouldn it make sense to replace it with a quality part ? You really should do new piston & rings while your at it..
If not - you might be doing it again allot sooner than you would like..

Your local bike shop should be able to get one for you..

Hope this helps !!
rate me good ;o)

Jul 14, 2009 | 2003 kawasaki KX 125

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