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Have you confirmed that they are interchangeable? I’m fairly certain those KDX engines were from the 89-90 KX’s.. What year KX250 engine are you using? Assuming it’s newer, it’s not likely to fit. The 92-04 Kx250 engine cases were different from the 91’s.
You could try having a new 1st and 5th gear made by a machinist, which won’t be cheap, or see if they can source replacements in your desired size which is entirely possible.
I've been considering this:
https://www.thumpertalk.com/forums/topic/902713-91-94-kdx-trans-into-a-…
Good luck!
I’ve had a kx250 in the stable for a long time. Raced enduro, hard enduro, desert, 24 hour, endurocross etc on it. Fun bike and pretty dang capable. Like any bike, it comes down to the rider.
I ran a 13oz fww, slightly retarded ignition, fmf gnarly, 18” wheel for the main changes. Other things were personal preference.
Oh and an IMS tank. It’s worth searching for the ims instead of the Clarke one, better fit and feel for the KX.
2007 KX250 FYI
Acerbis makes 11liter tank too :-)
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