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Hello guys, Dio from Greece here, I’m in the process of rebuilding my ‘89 KDX200-G the last 3 weeks, everything goes to plan, I’ll update with photos soon!

Today I flushed the antifreeze, but when I tried to unscrew the venting bolt , to lose the air , I broke the bloody bolt...

Could u please help me guys what part shall I get now?

Many thanks in advance!

Dio

Sorry for my bad English... I tried to bleed the air from the coolant, by unscrewing the bolt at the top of the engine, but it was probably rusty and broke, as I see it I’ll have to find the whole lot of the top engine

Did the aluminum housing get damaged? Was it just the bolt that broke? If it is just a bolt,a local dealer may have it. If not, see if it is a normal bolt and can be replaced by a normal metric bolt.

The housing is ok, I cut the top head of the bolt, the rest stayed inside :(

I’m using my mobile at the moment and doesn’t let me to upload photos, tomorrow from work I’ll post photos through my desktop pc

Take the part off the bike.

penetrating oil on what is left of the bolt

If there is not enough to grab with pliers, grind the top smooth.

hold the part in a vise (preferable drill press vise)

Get a left hand (ran in reverse) drill bit, drill a hole through the bolt. It may come out while being drilled in reverse.

If not, get a bolt remover and tap it into place and turn it free. (EZ out)

Thanks a ton man, I don’t have a bolt remover, I will try to reverse drill it and hope it comes out!

I’ll post an update

I second the reverse drill bit & penetrating oil.

This is how it looks right now, i'll give it a go this afternoon and let you know how this works!

You HAVE to take the part off. If you drill through it, then you send drill shavings into the coolant, pump, radiators, etc.

I still have a long way ahead of me.. but i really love my KDX and i will make it a beauty!

Thanks for the picture. We didn't get that model in the USA, so some of us really like seeing the ones we have not seen much of.

This is a 100% Japanese model and funny enough when i rang Kawasaki Greece to obtain parts codes they told me off , cause these bikes where never sold in Greece and they told me that came from USA.. i willupdate with more photos soon

Vesrah makes good parts!

You might want to change your signature to 1989 KDX200-G1 or similar.

Thanks man! i have ordered a V-Force reed valve V313A and then i say to myself - the boot needs to be changed as well ... another 130euros for me, as i can only find it on ebay , and half the price is for shipping to Greece.. and the journey continues as i see my wallet getting smaller, my wife is a bit anxious but hey what can you do the show must goes on!

You are welcome. If you don't mention that it is a "G" model, a fair amount of USA people will think you have an "E" as they are used to. Some parts are the same, and some are not.

Sorry to hear that it needed a boot as well.

When buying dirt bike parts, it is better to ask for forgiveness than permission.

''When buying dirt bike parts, it is better to ask for forgiveness than permission. ''

Hahahaha, wisely spoken man! ill bear this in mind!!!

I’m waiting for lots of parts to arrive, mostly from the
USA I will post updates soon I hope!