A few questions about my 94 kdx200

[ubareddition]

Yeah tried that too. That's what stripped it First.

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[Friedom]

Yeah tried that too. That's what stripped it First.

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Cool. It's helpful once you've got the slot for a flathead in there.

"Good job, guys. "

[ubareddition]

Installed new gasket and new piston and new wrist pin all with lube.

With a little help from a friend I slid the jug on. Bolted the head on. And put the reeds on.

assembled the governor shaft and the kips cover.

Put the motor in the frame.



Installed the new front brake lever.



Installed the new rear wheel bearings.

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[ubareddition]

Home Depot was out of stock of the normal small cutting disks so I got these instead.

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[ubareddition]

Carved a little slot. Put a flat head bit in there and it just shattered with the impact

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[Friedom]

More bits, less force?

[Friedom]

You know I'm not sure how large these bolt heads are, but you could perhaps put a good sized nut on it then weld it. The cavity makes a nice space for the spot weld. Then use a wrench to turn the nut

"Good job, guys. "

[ubareddition]

clamped a vice grip onto a flat head screwdriver and used that for extra torque. Twisted the end of the screwdriver around.

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[Friedom]

Wonder if some helpful PO used red Loctite.

"Good job, guys. "

[ubareddition]

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[Friedom]

Yuck. That's in there.

"Good job, guys. "

[ubareddition]

Just tried heating it up with the map gas torch did noting. So I welded in my last flat head bit and...

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[KDXGarage]

Any chance to grind it out?

[Friedom]

Starting to look like that's your option. Unless you can weld fill it with material enough to get it above the surrounding surface. I've also heard of using a tube of something that won't weld(Copper? Brass? Aluminum? ) To contain the weld area as you're building up material.
Amazing how one little thing can be such a hangup. That diamond tip for your Dremel will be helpful. I used the same one to eventually extract a shift drum bolt with a broken ez out in it. Don't use ez outs on something that's that stuck, btw.


"Good job, guys. "

[ubareddition]

So I gave up on the caliper for now. I just wanted to see if the bike ran. Got it all together. Got it started after a few kicks. First off I didn't tighten the kickstarter spring enough. It does not come all the way back up after a kick. So there's that. Got it started seemed to run good. Let it warm up a little. Checked the coolant. Seemed good. A little smoke. Figured from assembly burning off excess oil. Took it up the road to break it it. Ran fine for a quarter mile then it just died. Rear tire locked up almost went down. Pulled in the clutch downshifted. Got the bike to restart but it was bogging like crazy no power before it finally died. Clutch seemed to be locked up. Even pulling the clutch wouldn't let me push it out of the road. Finally got it out of the road and pulled it home. Pulled the spark plug. Fine. No fouling. The clutch oil seemed a little low. Barely in the viewing glass when tipped to the side. Added oil and pushed it around that seemed to help the clutch a little. Still seems stiff in gear with clutch pushed in. Idk what happened there.

So still trying to figure out why bike won't start. Put in line spark plug tester on it. It's got good spark. Figuring it's got fuel. Petcock is on. And it's a brand new rb carb. So I put the compression tester on it and after 6 kicks holding the throttle wide open its got less than 30 psi of compression. So after some considerable swearing. I've calmed myself enough to write this. This bike is a curse. Regardless motor has to come out and see what happened. But I'm really bummed. I thought I was done with this bike.

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[ubareddition]

If anyone wants a really good deal on a bike I'll be accepting offers as is. Before I start looking at it tomorrow.

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[KDXGarage]

Maybe it is something small. Breathe, if you can.

[Friedom]

What he said. You're so close, might as well figure out what you're up against.

"Good job, guys. "

[ubareddition]

When I get home from work I'm gonna pull the cylinder off and have a look.

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[ubareddition]

Just out of curiosity. I can't stop thinking about it at work. What is the compression supposed to be.

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