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weird... I noticed smoke pouring out of the front area, realized the kips cover was very loser and about to fall off. no good, tightened that up with much aggravation about the top bolt location. wow that's a bad design!

then, moved on to a quick test ride, bike didn't want to idle like it normally does, so I adjusted the idle screw a little, and ten kicks later it fired up, idled, slowed until it stalled.

that's odd, like it ran out of fuel?

tapped on the float bowl, kicked it another ten times and it finally started again.

this is normally a one kick bike, hot, cold, whatever.

the only other change made this afternoon was I cleaned the air filter.

ideas?

Air filter is too wet, or over saturated in oil?
What year bike?

6 Riders wrote:Air filter is too wet, or over saturated in oil?
What year bike?

1997, air filter was cleaned thoroughly, left in the sun till bone dry (water) and barely coated (oil) when I installed it.

maybe I got some junk in the idle circuit?

I'm surprised just how many things are taking lose on this beast

OK, I know this may sound condescending, but are you out of gas? The KDX has a "reversed" petcock and many people make the mistake of having "just enough gas" to use reserve, but have there petcock turned the wrong way....don't worry, you wouldn't be the first, or last to do this.

plug

6 Riders wrote:OK, I know this may sound condescending, but are you out of gas? The KDX has a "reversed" petcock and many people make the mistake of having "just enough gas" to use reserve, but have there petcock turned the wrong way....don't worry, you wouldn't be the first, or last to do this.

about half a tank is unfortunately

newbbewb wrote:plug

swapped it, no change

did you knock the air filter boot loose and letting air in more? Changing the fuel delivery and jetting? Just sounds familiar to when I had a get off and bike rested on a sapling and pushed my airbox kinda cocked on carb. It started once and died and couldn't get it to start for the life of me. Took a good look at it and seen that and whalla first kick again. Pain in the ass using a dime to loosen the clamp to put it back on right on the trail.

ICRage42 wrote:did you knock the air filter boot loose and letting air in more? Changing the fuel delivery and jetting? Just sounds familiar to when I had a get off and bike rested on a sapling and pushed my airbox kinda cocked on carb. It started once and died and couldn't get it to start for the life of me. Took a good look at it and seen that and whalla first kick again. Pain in the ass using a dime to loosen the clamp to put it back on right on the trail.

I'll give it another look. thanks for the heads up guys :-)

edited:

apparently the idle screw backed out, or someone played with it. have it 1/4 turn positive, and it fires and idle perfectly now.

the front kips cover was about to fall off, and the orings around the exhaust header were falling apart, so there were noise/air leaks everywhere.

remedied that with some fantastic silicon-on-a-roll that sticks to itself with a little warmth and pressure:

so now it's shooting all the noise out the back instead of lots of odd directions.

quick inspection on the piston and I can't feel these lines

with a finger nail so it should last till winter.

that's a screen shot of a video clip, it won't play no matter how many times you click it :D

holy hell, pull the jug and clean that crap out.

newbbewb wrote:holy hell, pull the jug and clean that crap out.

The protective layer of black gunk? ;)

I would. and if kips covers are falling off and the piston looked mildy scuffed, I'd be ordering a top end gasket kit just so I could pull everything, clean and use some blue loctite to put it all back together. use manual for torque specs.

newbbewb wrote:I would. and if kips covers are falling off and the piston looked mildy scuffed, I'd be ordering a top end gasket kit just so I could pull everything, clean and use some blue loctite to put it all back together. use manual for torque specs.

I cleaned the mating surfaces, and blue loctitd everything. the her gasket I ordered from eBay never arrived, but the base gasket did. son add I get a head gasket I'll pull and clean everything. properly