A few questions about my 94 kdx200

[ubareddition]

I found this on ebay. I messaged the seller to send me more pictures and ask more about the condition.

http://m.ebay.com/itm?itemId=3915494922 ... Watch=true

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[Friedom]

Edit: Wait that's not a case half! Much easier to swap out! Something flexed or whacked it pretty hard!

"Good job, guys. "

[ubareddition]

Trying to keep busy while I'm waiting to hear back from the ebay seller.

I got my air filters washed out. The second one is much larger than the one that came off my bike. It was in a box of spare parts I got when I bought it. I actually have a whole air box too but it's different than the one on my kdx. Maybe an h series?

I also started to clean up some of the other pieces before I reinstall them.



After.



Replaced the seals in that cover too.
Might start putting the valves and studs back in the topend.

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[KDXGarage]

Thanks for the continued thread and pics / info.

On the air filters, the same air filter is used for 1989 - 1994 KDX200, 1995 - 2006 KDX200 and 1997 - 2005 KDX220R.

What did you use to clean up the outer clutch cover?

Buy a new soft bristle toothbrush and use some Dawn detergent and water on the seat cover to try to clean it up some.

[ubareddition]

I got a cotton polishing pad for my dremmel with different grits. Soap and water. Blow dry with compressed air then oil the bearing for the clutch rod.

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[KDXGarage]

Thanks for the info. It looks a lot better.

[ubareddition]

Can someone help out with explaining kips valve reassembly and timing. Because the manual has me very confused and it does not work the way they want you to do it.

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[Friedom]

A lot of it is in putting them in, sliding the rack, and figuring it out. For me the hard part was getting the center valve properly aligned.

"Good job, guys. "

[ubareddition]

A lot of it is in putting them in, sliding the rack, and figuring it out. For me the hard part was getting the center valve properly aligned.

"Good job, guys. "

Thats exactly where I'm at. When I pull the rod all the way out in what position is that center valve supposed to be in? like this? Or closed

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[Friedom]

The valve should be fully open when the rod is fully extended.

"Good job, guys. "

[ubareddition]

And when the rod is fully pulled out the timing marks should look like this



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[Friedom]

Yeah, looks right. Look in the exhaust and verify everything is right when extended


"Good job, guys. "

[ubareddition]

it is. Yessssss!

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[ubareddition]

So I figured I'd start assembling what I can while I wait for the inner clutch cover to come in. I did order that one off ebay even though I did not hear back from the seller. Trying to keep this project moving despite the many road blocks.

There's my very clean and nice looking topend. Was considering painting it something glossy to protect the porous nature of it and make it easier to clean but I'm not sure.







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[ubareddition]

I cleaned up my studs a little before putting them back in. I noticed there's one that's shorter and different than the others. But I figured out it goes in the center position.



Then here is my dirty bag of kips valves. All caked with carbon.



Started cleaning up the valves







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[ubareddition]

Noticed a little dammage to one of the valves not bad.

Cleaned up this little guy too.










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[ubareddition]

Jason I took your advise and cleaned up my seat cover. Came out nice.


Finally I scrubbed all my muffler parts with soap and water rinsed and then let them soak in soap and water overnight.

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[ubareddition]

there she is all clean. Now i can start disassembly without worring about dirt getting in my engine.

Ok first off about the kips valves. It seems to me they are working properly. They all spin. However. They were not hooked up so they werent working. When i took off the cover on the kickstarter side to get at the rod and such this fell into my hand.
Not the arm but the circular thing. It seems there should have been a circlip on the end of the rod that goes into the head. So that when the arm swings out it could pull that rod out. But that wasnt happening.


Heres a closeup of that rod i was talking about. The second circlip was gone.

So theres that. Now on to the bad and the ugly.

Now if you guys remember this post from when I first took the bike apart. I need to get those circlips.

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[ubareddition]

So I called the dealership. That part number is 482j4000 it was superceded by part number 482k4000. That's the part number I'll pick up later.

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[ubareddition]

I picked it up and installed



The overnight soak in dawn did nothing for the silencer parts. The manual suggests oven cleaner for the really baked on parts. And these are really bad.







I cleaned off some off the easy to get to stuff with the wire wheel. It looks like one of the pieces is broken and missing some pieces. I'm not really sure because idk what it was supposed to look like.



I also painted my clutch and flywheel covers. Going for something a little different.

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