95 kdx 200

[jimmy97]

does this look right to anybody? this is at tdc .

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[SS109]

I assume your asking about the piston to deck difference? It looks deeper in the hole than I have seen. Does it have two base gaskets on there or an extra thick one?

[jimmy97]

it actually has no base gasket on it in this picture

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[jimmy97]

I have rebuilt many 2 strokes in my day. and have never seen a piston this far in the hole at tdc. don't get me wrong, this bike rips! this just looked a little off to me.

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[Vossman]

Keep us posted on what you figure out. Never see one that low.
Heres my old YZ motor.

[pumpguy]

Maybe someone put in the wrong piston or con rod. Did you happen to check the compression pressure before the head came off?

Is the piston crown this low @ BDC below the bottom of the exhaust and transfer ports?

[cornishwrecker220]

It's quite normal for there to be a gap .... I'm sure if you placed a ruler across the top of your piston it would be level with the top of the jug .... It also has to accommodate expansion .

[KDXGarage]

Solder for squish measurement time??

[jimmy97]

squish without head gasket. . . . 148 thou , plus .010 for head gasket for a total of 158 thou or 4.013 mm

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[jimmy97]

uh, yeah. Just looked it up , I'm about .100" over ! Lets start from the beginning.
I bought this bike for next to nothing, case was split due to a blown output shaft bearing (the one behind the front sprocket) guy said everything was there. well the crank and clutch was missing. no biggie. purchased a used crank off eBay along with a new rod and bearings sent this to RB to have it assembled, since he was doing my head and carb anyways. never had a chance to compare crank nor rod side by side so it looks like a wrong part was put in. piston is a stock piece. I guess this means I can run 87 octane has then ! I've been riding this bike for about 2 years this way. it runs good. I just gotta spin in like a 125 . oh well. I'm still gonna send it !

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[jimmy97]

this is piston at bdc

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[jimmy97]

this is piston at bdc

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see pic

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[jimmy97]

this is piston at bdc

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see pic

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unless anybody has any advice before I re-assemble?

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[jimmy97]

stroke is measuring right at 58 mm. it looks like the only thing it could be is the wrong length con rod was installed

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[jimmy97]

this is the exact rod that is in my bike now. looks like I was in a hurry and ordered the wrong year rod

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[KDXGarage]

If it is too short, how do you have proper compression?

Congratulations on your bravery and fearlessness to run a $49 connecting rod kit.

[pumpguy]

Wrong rod could be the problem. OEM rod # 13032-1210 is only listed for '95 & later H Series 200 & 220.

Looks like old man Murphy strikes again

[david]

The rod is the same from '89-'06
http://www.hotrodsproducts.com/ProductI ... tem_id=889

The one your got is 3mm too short.
http://www.hotrodsproducts.com/ProductI ... tem_id=863

[KDXGarage]

following photo from phospher site (good job to him!)



Since you gave about zero background info, did you just install the rod kit? What have you JUST done and how did it get to the point in the picture? Thanks.

[Vossman]

Cool you got it figured out.