A few questions about my 94 kdx200

[Friedom]

That doesn't look like a stock silencer.

"Good job, guys. "

[ubareddition]

It says it is on the outside casing. I can take a picture of it later.

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[Friedom]

Well one of us doesn't have stock, cause mine says it on the casing too but it doesn't have that fancy blade thingie in it. I think that's a FMF turbine core II.
It's a good thing if it is :)

"Good job, guys. "

[ubareddition]

Hmm the bike did have a fmf sticker on it. I just figured it was for the gold series woods pipe.

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[KDXGarage]

DO NOT let the EZ Off soak for long on aluminum. A few minutes and rinse

[ubareddition]

My new case came in. Looks good. Didn't have any time to do anything before or after night school. But tonight we will see how much I can get together.



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[ubareddition]

Does anyone know what the proper break in procedure is for a new rebuild?

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[Friedom]

Does anyone know what the proper break in procedure is for a new rebuild?

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There are many trains of thought here. Mine was simple: warm it up and ride it. The rings will seat and it'll be great.
Check the torque on your head bolts after the first couple rides though.
Read around. Some people say hat cycles and baby it in, some say you only get that first time to really set it for running under load. They both seem to work.

"Good job, guys. "

[ubareddition]

The internal parts of the silencer are made from steel. So I coated them with oven cleaner. Let sit for 5 min. Brushed them a little with a wire brush. Rinsed them. Now I'm soaked them again with oven cleaner and I'm going to wait a little longer to see how much of the baked on oil I can remove before I attempt to weld that broken piece together



The casing of the silencer is aluminum so I lightly sprayed it with oven cleaner wrapped shop towels around a pipe and lightly scrubbed the inside like you would clean a gun with a ramrod. Then rinsed it throughly with water.








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[ubareddition]

Any tips on stripped Allen head bolts for the rear brake. The slider pins that hold the pads in place? I don't wanna spoil anything but that's the only thing holding me up right now.

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[Friedom]

Cut a slot with a Dremel and use a flathead to get them out. Then you can replace them or use again.

"Good job, guys. "

[ubareddition]

Cut a slot even though they are flush with the caliper surface?

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[Friedom]

If you're able to do it without damaging the caliper, yes. Small cutting wheel usually does the trick. There are other methods, but this has worked well for me.

"Good job, guys. "

[ubareddition]

I'll get some smaller cutting disks.

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[Friedom]

Alternately you can weld a Allen key into place, but that's a bit harder to clean up and make useful afterwards.

"Good job, guys. "

[ubareddition]

So here's what got done last night till 330 am when I couldn't do it anymore. Cleaned the new inner clutch cover. Took all the old seals and bearings out. Then took all the new seals and bearings out of the case I cracked. Transfered them over. Installed the cover. installed the outer clutch cover with new seals.

Installed new wrist pin bearing.

To be continued

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[ubareddition]

Alternately you can weld a Allen key into place, but that's a bit harder to clean up and make useful afterwards.

"Good job, guys. "

Tried that already. Didn't work. Very hard to weld a good bead all the way around. It's a very small area that's exposed.

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[Friedom]

Alternately you can weld a Allen key into place, but that's a bit harder to clean up and make useful afterwards.

"Good job, guys. "

Tried that already. Didn't work. Very hard to weld a good bead all the way around. It's a very small area that's exposed.

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True. I've never had any luck doing it either, but the heat you applied should help break it loose.

"Good job, guys. "

[ubareddition]

I'm going to go to home Depot later to get small metal cutting disks for the dremel.

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[Friedom]

Do you have one of those impact tools that will turn something a small but powerful appoint when you hammer it? I've had great success getting things loose with one.

"Good job, guys. "