New swedish kdx rider

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Gotanubike
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New swedish kdx rider

Post by Gotanubike »

Hmm no weld on mine. Just slides right off after removing the axle
1990 KDX200
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96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
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Tbar
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New swedish kdx rider

Post by Tbar »

Yes blob is on the axle, had to take the rear weel off today, noticed a spoke missing and one broken.
With wheel off i maybe take the rust of the disc and change breakpads. I need it working wednesday, have a friend over for some riding fun. Bearings seems ok. Lots of dirt everywhere...
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6 Riders
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New swedish kdx rider

Post by 6 Riders »

Gotanubike wrote:Hmm no weld on mine. Just slides right off after removing the axle
The adjuster is welded to the axle...not the nut....I have seen some that have the adjuster "freed" from the axle, but they are supposed to be welded on on that side.
newbbewb wrote:^what he said.
masterblaster wrote:Man 6 riders you rock.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually type
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Gotanubike
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New swedish kdx rider

Post by Gotanubike »

6 Riders wrote:
Gotanubike wrote:Hmm no weld on mine. Just slides right off after removing the axle
The adjuster is welded to the axle...not the nut....I have seen some that have the adjuster "freed" from the axle, but they are supposed to be welded on on that side.
+1 that's what I was trying to say
1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158
Tbar
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New swedish kdx rider

Post by Tbar »

So today I was going to check out the KIPS gears and started to take the top off.
It worked out ok, i supported the leftbolt shaft and read the manual several times, but i got stuck on the nut holding the main rod in position, it was tighten as if it was welded there, I could lift the idle gear and it looked ok, both side valves and main exhaust gear seem to need the rod out to be lifted for cleaning and inspection, anyway... When i had nothing else to do and had already exceeded my mechanic skills I decided to remove the whole cylinder to take it to a friend of mine with better tools to get that stubborn rod bolt removed ( I really want to inspect those kips gears). I sprayed WD40 on the cyl.bolts and took the left kips cover off, alot of spooge was hiding under that one, actually packed with it. Cleaned it for a while before I started to attack those cyl.bolts.

This is what i discover... Is there a missing part in my piston?, it looks like a part is missing on intake side.
Someone must have broken it when they put it on there, I didnt notice any piece fall out when i took cyl. Off. Wierd..... And scary ,could that piece have fallen down into gearbox?
Image
Getting a new pistonkit now. Happy the rodbolt was stuck so i had to take cyl off, cant see much damage in the cylinder. May need a cleanup.

Kips moving smooth moving the rod in and out all valves turning.
Image

Ty for excellent newbthread and other info on this forum, couldnt have done all this without it!
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Gotanubike
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New swedish kdx rider

Post by Gotanubike »

Looks pretty good and clean. That piece of missing piston skirt is strange, though. I'd guess if it broke off inside the motor, it got pushed out the exhaust.

The retaining screw(the one that is really hard to remove) along with the black rod guide/bushing does not absolutely need to be removed. If you remove the collar wheel on the end of the rod, the rod can slide out the left side of the motor.

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1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158
Tbar
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Re: New swedish kdx rider

Post by Tbar »

Tyvm that is a better way than trying to remove/damage the screw, excellent!
Had another issue with the main exhaust valve, manual said to pull gear out abit before taking rod out but my gear is stuck, i could take the valve out after removing the small ring locking the valve to the gearaxle but gear doesnt want to come out, i put everything back and kips runs smooth. I will have another try tomorrow, finally going to maintance my gears! :grin:
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New swedish kdx rider

Post by Tbar »

So left valvepinions didnt look good, need to replace it, your idea, taking rod out on left side worked, perfect.
Mounted and dismounted valves a few times, easier than i thought it would be.
Checked my cylinder again, closer than before, i have a small crack between 2 exhaustports :cry:
Anyone know if a 94 cyl would fit a 90 kdx?
A mxshop close to my home have a rebuilt 94 cyl. They have a trade in system, cost my broken cyl + 350 $ to get it, labor is expensive in sweden, we are born free and taxed to death.
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Gotanubike
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New swedish kdx rider

Post by Gotanubike »

A 94 cylinder will fit. But you may just find it cheaper and more practical to send out your cylinder to have it replated. And 90% of the time, those shops are able to repair any cylinder damage too.

I purchased a newly plated cylinder from a user on this board. They welded a cracked spot above the center exhaust port and the nickel silicon carbide(nikasil) plating on the bore stands up much stronger against wear than the factory electrofusion plating.

They have a branch in the Netherlands as well, though you may be able to find a service in Sweden

http://en.powerseal.nl/
1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158
Tbar
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Re: New swedish kdx rider

Post by Tbar »

i have been looking around for a swedish nicasil replater and it seems all of them send their cylinders to nl or uk for replating. :grin: The 94 cyl. at the mx shop is such a cyl. Tyvm for your reply, its not far to travel to the mxshop, may take a trip with my valves to see it they fit the 94 cyl. :grin:
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diymirage
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Re: New swedish kdx rider

Post by diymirage »

send it to the Dutch, them guys rock
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
Bitteeinit
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New swedish kdx rider

Post by Bitteeinit »

Gotanubike wrote:A 94 cylinder will fit. But you may just find it cheaper and more practical to send out your cylinder to have it replated. And 90% of the time, those shops are able to repair any cylinder damage too.

I purchased a newly plated cylinder from a user on this board. They welded a cracked spot above the center exhaust port and the nickel silicon carbide(nikasil) plating on the bore stands up much stronger against wear than the factory electrofusion plating.

They have a branch in the Netherlands as well, though you may be able to find a service in Sweden

http://en.powerseal.nl/
How much did you get the cylinder for? I ask because I was recently offered a used cylinder for 40$... Heavily scratched (almost rusted on the inside or something) and can't be plated, but could be sleeved of course. The rest was in good shape. Seemed like a decent price but I'm wondering what the going rate is for a bad cylinder.
Tbar
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Re: New swedish kdx rider

Post by Tbar »

Replating in NL incl weld of crack 375$.
I ve sent it, now wait 4 weeks.
Time to get new kips valves and get the spokes in rearwheel fixed.
Cleaned the airfilterbox, was alot of stuff on wrong side of the filter.
What should i do now, check the linkage on shock absorber?, or is that to difficult?
Have to remeber how to put everything back on the bike too......
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Gotanubike
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New swedish kdx rider

Post by Gotanubike »

Reassembly of kips is easy with the basic idea that with the rod pulled all the way out, all valves should be open. There are dots on the tops of the gears to mark the alignment.

Image

Spokes are good, also wheel hub bearings, maybe water pump seals if coolant in the oil, fork seals which is a bit more advanced requiring a damper rod holder tool(link to that in my signature). Brake pads, air filter clean/oil, sprockets, chain(110 links) 10w30 or 40 motorcycle oil(may be different in Europe) but generally any motorcycle oil or automatic transmission fluid
1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158
Tbar
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Re: New swedish kdx rider

Post by Tbar »

So i sent my cylinder to the dutch, them guys, well, do not rock, got it back, and right valve didnt fit without abit of work from a grinder, anyway, putting things back is not that hard if u are not as stupid as i am, the pin with a bulb in the middle is supposed to be in a certain place. Yes i know that now.
Kips was stuck and i had to have dinner (blood sugar level was LOW), before i figured out that the pinbolt in the middle was locking my kips from moving.
Still waiting for my rearwheel spokes before I try to start the now put tghtr kdx. New piston and fluids, soon we will go riding again.
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