1986 KDX200 Cheap Flywheel
Posted: 09:44 pm Oct 22 2015
Hello! This is my first post on KDXrider, and I hope I will help A LOT of people. I haven't been able to get around to making this post (probably been about a year-ish.. whoops 
) ANYWAY! It all started when my 86' kdx200 ended up revving too high and shut off. I found out that it was the flywheel magnets. The previous owner re-epoxied the magnets (I think, that or it was original) and they decided to come off and crush my coils up along with breaking beyond repair.. So like any other person I went online to find out how much one of these magneto rotors are.. found out that they only made them for three year models 86-88... also found out that it was impossible to find a used one on ebay... also found out that an OEM one cost around $400-500. I was 18 at the time and decided that I wasn't going to spend $450 on a little metal bowl with magnets 
So I lurked on the forums here for a little and found out that the Kawasaki Tecate 3 and 4 rotors fix on the bike, and they aren't too expensive for a new one because they made a bunch of them that no one bought ($150 brand new). I also found someone saying that the woodruff key hole is at a different location (that means that the timing is different). They also mentioned that you might be able to cut a new keyway to match the original one.
I hadn't found any real writeups or posts of people actually doing it though. Then I got enough balls to try it out.
I bought $150 tecate 3/4 flywheel from Ricky Stator (also bought new ignition coil to replace the smashed up one). I got the flywheel and took it to multiple places and people said they could cut it due to it being a tapered shaft etc. Finally went to a CNC milling shop and had them line up the original and the new bowl (you line them up by the firing marks / timing marks) then "wire" out a new keyway at the original degree. They did it for $100, but you may find someone to do it cheaper. Here are some pictures of the bowls themselves in the posts below.
Here is a link to the Tecate 3/4 flywheel for $150 Part# RS100T3F
http://www.rickystator.com/product/kawa ... 4-flywheel
) ANYWAY! It all started when my 86' kdx200 ended up revving too high and shut off. I found out that it was the flywheel magnets. The previous owner re-epoxied the magnets (I think, that or it was original) and they decided to come off and crush my coils up along with breaking beyond repair.. So like any other person I went online to find out how much one of these magneto rotors are.. found out that they only made them for three year models 86-88... also found out that it was impossible to find a used one on ebay... also found out that an OEM one cost around $400-500. I was 18 at the time and decided that I wasn't going to spend $450 on a little metal bowl with magnets So I lurked on the forums here for a little and found out that the Kawasaki Tecate 3 and 4 rotors fix on the bike, and they aren't too expensive for a new one because they made a bunch of them that no one bought ($150 brand new). I also found someone saying that the woodruff key hole is at a different location (that means that the timing is different). They also mentioned that you might be able to cut a new keyway to match the original one. I hadn't found any real writeups or posts of people actually doing it though. Then I got enough balls to try it out.
I bought $150 tecate 3/4 flywheel from Ricky Stator (also bought new ignition coil to replace the smashed up one). I got the flywheel and took it to multiple places and people said they could cut it due to it being a tapered shaft etc. Finally went to a CNC milling shop and had them line up the original and the new bowl (you line them up by the firing marks / timing marks) then "wire" out a new keyway at the original degree. They did it for $100, but you may find someone to do it cheaper. Here are some pictures of the bowls themselves in the posts below.Here is a link to the Tecate 3/4 flywheel for $150 Part# RS100T3F
http://www.rickystator.com/product/kawa ... 4-flywheel
