Red '84

[mtbill]

Thanks, good tip.

While I'm waiting on the case to show up, I figured I'd finish putting everything together to see how it looked.
Everything's together but the rear fender.



Buttoned up the rear fender & test rode it today (in the rain). Runs good, shifts & rides great, leaks oil...a lot of oil. Now I'll re-pull the engine & tear it down to replace the cracked case.. Found the PO welded the shifter to the shift shaft also. I'm feeling like the " to stupid to stop" member. The money pit keeps getting deeper. I've got too much invested to quit now. It's gotta' end sometime.

[david]

You're almost there. Looks great. When your done, you won't have to fix anything for years, unless you ride hard.

[mtbill]

Cases finally showed up. USPS lost them for a week. They were lost on a shelf in the local post office. The ladie did say she was sorry though

Ground the shifter off of the shaft & somehow saved the shaft splines. A used oem shifter showed up yesterday from e-bay.

I made my own case spliter with a 5"x5" piece of 1/8" aluminum. Used a hole saw to make a spot for the crank shaft to go through, drilled 3 holes to bolt it to the case and 2 more holes for puller bolts. It took 15 minutes to make & worked like a charm. Everything is back together except the fly wheel & covers. All new engine seals & gaskets. It all looked spotless inside. bearings are great, gears are perfect. Amazing for a 30 year old machine. I'll post some more pictures tonight.

[B737driver]

Wow! Unbelievable makeover. Looks great.

[mtbill]

Here's a picture of the case splitter I made. Just bolt it to the case & mount the puller.

I hope this isn't a problem

Cylinder looks good

Almost back together



I don't believe it. A magnate fell out of the fly wheel. Looked like someone siliconed it in with rtv.
THEN... I snapped a ring installing the cylinder....then.....I snapped.....

See ya' later!

[mtbill]

Can anyone tell me forsure if the rings for an ''86 or newer will fit my '84 piston. I see from other posts that pistons will work but I'd rather not spend the money if the rings will work. Also, when shopping for NOS rings, I found that Kawasaki uses 13008 for rings & then adds a dash & more numbers to designate what engine. I can't seem to find out what comes after the dash on my '84 200. 13008-??

I may post this on general Q&A also.
Thanks

[Dekon]

This might help you out.

https://www.kawasakiepc.com/SystemSearc ... N=31873032

[red84]

what are you hoping to get for it when finished?

[mtbill]

Sorry, it's been awhile I got the engine back together a month ago but had some problems getting the kick starter to engage and the clutch to disengage. Should have paid attention to the thrust washers. I can remove the rear brake lever, clutch cover, clutch basket & kick start assembly in about 6 minutes now. I never did find a ring for it so I bought one for an '86. It fit in the groove ok but didn't close completely because it hit the alignment nerd. I filed down the ring on both ends until it fit. It seems to run great, with good compression. Soooo....here it is!!

red84, I posted it on craigslist for $900. I've got $935 in new & used parts in it. But that's ok, $300 goes to Christian charities no matter what I get for it. It was fun & I spent some good time with my son. Life is Good!

[Joshmcmillan]

Looks great!!! Good job with the plastics!

I've done the same thing with the thrust washer, had it apart and back together many times before, then one time I decided the washer went on the other side of the clutch, took me a while to figure out why it all jammed up when it was back together :P