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Does anyone happen to have a ID measurement from magnet to magnet or a flywheel already off they could grab a quick measurement from. This is for a 88 but the newer ones should be the same if not very close. Thanks

Anyone?

Not yet, no.

Hmm, well maybe tomorrow..

Give it time. If you don't get an answer in a few days I'll pull mine and get you the measurement. Remind me.

Yeah, im sure someone has one lying around they could measure. Thanks man

I think im gonna make a flywheel puller for this thing, any one got a picture of one just for reference.

Roadhazardguy wrote:I think im gonna make a flywheel puller for this thing, any one got a picture of one just for reference.

Of a flywheel puller?

You can buy a flywheel puller for around $10. I wouldn't bother trying to make one. What are you after anyway?

The large thread is left hand thread also.

The 86-88 flywheel isn't threaded in the center like every other kawasaki dirtbike flywheel ive seen. It has three threaded holes for a harmonic balance type puller except it needs to be real small.

Go to the auto parts store and look for a steering wheel puller. If they have one I bet it will be cheep. They are like a small balancer puller.

Like this?

http://motionpro.com/motorcycle/partno/08-0160/

Get one that is triangular shaped with long slots (where the extraction bolts can slide to fit) - that way you'll have a tool that works with various radius patterns, including the C model flywheel.

So I made a puller and got the flywheel off and It's about 85mm magnet to magnet.

It wanted to know this because I got a stator from a 1975 G4 that has three coils and now that Ive compared them it looks like with a little modification I can make it work on the KDX. I'll probably end up rewinding all of the coils and two of them with 18ga magnet wire for some higher output. I'll put up some pictures if yall are interested.

Roadhazardguy wrote:It wanted to know this because I got a stator from a 1975 G4 that has three coils and now that Ive compared them it looks like with a little modification I can make it work on the KDX. I'll probably end up rewinding all of the coils and two of them with 18ga magnet wire for some higher output. I'll put up some pictures if yall are interested.

Yes, please post up some pics. I would love to see what you are doing!

Me too! BTW, just what is a 1975 G4?

Well I was going to post up pictures but I guess I can't unless I have photobucket or something?

OK so I started out by buying a flywheel/ stator assembly from a 75 Kaw G4 to replace the flywheel and points on my KD80 because it was not in the best shape... see picture (Already swapped it out and the rusty one is off the KD80, the G4 flywheel is on my KD80 now).
Left: 88 KDX200, Right: KD80


The KDX and the G4 flywheel both measure out to 85mm to the inside of the magnets. (ruler is setting on center hub but is lined up with magnet)



Here they are next to each other.



The G4 stator plate has little nubs to help hold the crank seal.


They were in the way so... I removed them.


The KDX plate is 110mm across.


The G4 plate is about 115mm across


I scribed a line all the way around where it needed to be.


Then I cut it off. I used a cutoff tool and a bench grinder to get it where I wanted it.


And it fits. The center hole has about 3/32nds all the way around it but it does clear, and flywheel doesn't touch anything either.



I need to go get the cases split and get the crank rebuilt so I can get further on this.

I can put the ignition coil on any of the three slots I want then clock the plate where I need it and then drill and slot the holes for the hold down screws. I figure I need to get it running first with the KDX stator then with a timing light take note of where it is sparking at. Then I can go from there to figure out where the G4 stator needs to be clocked at.

Any tips or advise is welcome.