Help ID pins found after rebuild
Posted: 04:57 pm Jul 07 2019
Ughhhhh, i have always seen these types of posts and think to myself 'how can you be so careless that you forget to put back a bolt/washer/pin/etc' yet here i found myself in this very situation.
The pins in question are about 5.75mm x 11.75mm and have a rounded side and a flat side with a 2mm dimple in the center. Both pins have the same rounded side and flat dimple side, which kinda made them stand out to me and left hopes someone may recognize what these went to. The pins did have some build up on them which made me thing it was an external part, but in the state of the maintenance when i got it means that grime could have been internal or external.
My first instinct was to check the gasket location pins on the jug, head, and KIPS covers - but all of those were well in place and overall too small to match the pins. I checked out the parts fisch and found 99% of the pins used are listed as "610: PIN DOWEL 4X8 - 610A0408" and all of them listed in the fisch were present. There are no other pins i could find in the OEM parts guide - so im leaning to say they are from another project and just got missed until just now.... but want to check with the community first incase anyone with lots of KDX maintenance and work recognized them with that unique dimple on each pin
I posted some photos below, take a look and let me know if you have any ideas!!
------------------------------More Background Info------------------------------------
Im wrapping up a restoration job on a 2002 KDX200-H8 and have been working though endless parts that were broken, stuck, or missing which has drawn this project out over a year now from the initial disassembly - so you can understand why its not all super fresh in my memory.
None the less, i finished a fresh top-end and extremely detailed KIPS cleaning and got the engine all buttoned up then started to move to the frame to install the swingarm and forks so i have a rolling chassis to mount the engine back in. Since I'm done with all the parts washing, i decided to empty out the washer and low and behold - two pins were sitting there in the bottom that i have no clue where they came from.
Full disclosure, i did work on another enduro bike, two other small 2-stroke engines, a lawn mower, and a few other small projects over the same period so its possible the parts are not even from the KDX. As far as the KDX was concerned, the bike was stripped down to the frame and had everything refreshed or replaced including every possible gear, chain, bearing, seal, front/rear calipers & master cylinders, cables, hoses, etc so it could have come from anywhere on the bike. The engine case itself was never split, and the side covers were not removed yet, so that only leaves the KIPS and top-end rebuild and exterior pins as possible contenders on the engine.
My first instinct was to check the gasket location pins on the jug, head, and KIPS covers - but all of those were well in place and overall too small to match the pins. I checked out the parts fisch and found 99% of the pins used are listed as "610: PIN DOWEL 4X8 - 610A0408" and all of them listed in the fisch were present. There are no other pins i could find in the OEM parts guide - so im leaning to say they are from another project and just got missed until just now.... but want to check with the community first incase anyone with lots of KDX maintenance and work recognized them with that unique dimple on each pin
------------------------------------------------------------------------------------------------
Thanks again for all the help along the way!!
-Rich
The pins in question are about 5.75mm x 11.75mm and have a rounded side and a flat side with a 2mm dimple in the center. Both pins have the same rounded side and flat dimple side, which kinda made them stand out to me and left hopes someone may recognize what these went to. The pins did have some build up on them which made me thing it was an external part, but in the state of the maintenance when i got it means that grime could have been internal or external.
My first instinct was to check the gasket location pins on the jug, head, and KIPS covers - but all of those were well in place and overall too small to match the pins. I checked out the parts fisch and found 99% of the pins used are listed as "610: PIN DOWEL 4X8 - 610A0408" and all of them listed in the fisch were present. There are no other pins i could find in the OEM parts guide - so im leaning to say they are from another project and just got missed until just now.... but want to check with the community first incase anyone with lots of KDX maintenance and work recognized them with that unique dimple on each pin
I posted some photos below, take a look and let me know if you have any ideas!!
------------------------------More Background Info------------------------------------
Im wrapping up a restoration job on a 2002 KDX200-H8 and have been working though endless parts that were broken, stuck, or missing which has drawn this project out over a year now from the initial disassembly - so you can understand why its not all super fresh in my memory.
None the less, i finished a fresh top-end and extremely detailed KIPS cleaning and got the engine all buttoned up then started to move to the frame to install the swingarm and forks so i have a rolling chassis to mount the engine back in. Since I'm done with all the parts washing, i decided to empty out the washer and low and behold - two pins were sitting there in the bottom that i have no clue where they came from.
Full disclosure, i did work on another enduro bike, two other small 2-stroke engines, a lawn mower, and a few other small projects over the same period so its possible the parts are not even from the KDX. As far as the KDX was concerned, the bike was stripped down to the frame and had everything refreshed or replaced including every possible gear, chain, bearing, seal, front/rear calipers & master cylinders, cables, hoses, etc so it could have come from anywhere on the bike. The engine case itself was never split, and the side covers were not removed yet, so that only leaves the KIPS and top-end rebuild and exterior pins as possible contenders on the engine.
My first instinct was to check the gasket location pins on the jug, head, and KIPS covers - but all of those were well in place and overall too small to match the pins. I checked out the parts fisch and found 99% of the pins used are listed as "610: PIN DOWEL 4X8 - 610A0408" and all of them listed in the fisch were present. There are no other pins i could find in the OEM parts guide - so im leaning to say they are from another project and just got missed until just now.... but want to check with the community first incase anyone with lots of KDX maintenance and work recognized them with that unique dimple on each pin
------------------------------------------------------------------------------------------------
Thanks again for all the help along the way!!
-Rich