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I just got a 1984 kdx200 off craigslist. I'm having trouble starting it, so I'm running through some of the steps. Fresh gas, new air filter, new spark plug...still no luck. Next I took the carb out and apart. When I removed the bowl, I found some chunky snotty boogers. I believe it's from water getting in from the rubber boot on top where the throttle cable enters. I clean the carb real good, had a look at the reeds, and put her back together. Still no luck starting it. I decided to pop the flywheel cover and have a look at the stator. As I started to remove the bolts from the cover, a couple spoons full of water spilled out. I removed the cover and see the flywheel is all snotty and gunky. I want to remove the flywheel, but don't have a puller. I'll have to get one tomorrow. I just wanted to get a topic going for any help that anyone can offer. This is my first project bike, and first bike I've worked on, so any help or suggestions would be awesome.

Not sure how to post pictures, but I'll try.

WOW! That looks bad. You will need a puller that is a plate with 3 bolts. The 27mm left hand threads puller is NOT for the air-cooled full-sized KDX's.

Good luck!

Thanks. Is there a chance the motor may be completely junk? Or is everything in there replaceable? Earlier on when I checked, the bike had spark. I guessing that's a good sign. I just hope I can bring this bike back to life.

It can be rebuilt. Inspect it all and see how it is.

Ok bought the puller and got the flywheel off. Here's what the stators look like.

The screws that hold the stator plate on are rusted up. I tried taking them out with a couple different Phillips bits, and they're wanting to strip. I sprayed them good with some rust buster, and I'll try again tomorrow. That's as far as I got for today. Anyone know a good website to order stators from?

I would let the rust blaster work and then try to hold of an impact driver for the screws before you strip them.

True, I'll see if I can borrow an impact driver from my neighbor.

get a hand impact driver that uses a hammer

looks rough

let the penetrating oil set for a day or so

Jason wrote:get a hand impact driver that uses a hammer

looks rough

let the penetrating oil set for a day or so

put some heat on the bolt heads too. (pen torch) then spray the penetrant. stuff wet rags to prevent fire or damage.

that impact wrench is a blessing of simple but extremely effective design.

If worse comes to worst, you may need to grind off the heads of the screws to remove the stator. Once off, you should be able to latch on to the shank of the screws with a Vice Grip or similar pliers and unscrew them that way.

Good luck.

you really dont want to heat the HEAD of the bolt, you want to heat the material that the bolt is screwed into.

Jason wrote:get a hand impact driver that uses a hammer

looks rough

let the penetrating oil set for a day or so

This ^. My handheld impact driver has been a lifesaver so many times! Even a cheap one like this would probably do the trick. I just searched for impact screwdriver at Harbor Freight...

http://www.harborfreight.com/impact-scr ... 37530.html


Good luck!