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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.

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

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.

Wow! Unbelievable makeover. Looks great.

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!

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

This might help you out.

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

what are you hoping to get for it when finished?

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!

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