Bottom End

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1Kam
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Bottom End

Post by 1Kam »

Hey my Name Is Kam & I have an 02 KDX 200 and I'm trying to rebuild my bottom end but I can't find the Kit for it , does anyone know where I can Find one ?
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Tedh98
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Re: Bottom End

Post by Tedh98 »

There is no "kit" for the kdx. You need to buy everything individually and get your or another OEM crank rebuilt.

You can buy the seals and or gaskets as a complete set, but they wont be OEM.
Last edited by Tedh98 on 07:58 pm Apr 12 2016, edited 1 time in total.
1Kam
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Re: Bottom End

Post by 1Kam »

okay okay , because every time I look up "Rebuild kit" for Kdx I NEVER Find one lol
david
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Re: Bottom End

Post by david »

You get 3 seperate 'kits'. Then like Ted said, take the rod kit and your crank to a motorcycle machine shop to have them build your crank. Then you reassemble everything else. You may or may not have to have your cylinder replated depending on the condition of it. If you need crank bearings, those are separate. You can get them from Kawasaki or go to your local bearing supply house and get some NTN or SKF replacements (6305JR2C3).
Connecting rod kit
Piston & ring kit
Gasket & seal kit
'81 KDX 175
'90 KDX 200
'07 Vulcan 2000 Classic LT (totaled 4/25/15)
'82 Honda GL500 (sold)
'96 ZXi 1100 JetSki
'98 STX 1100 JetSki
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Tedh98
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Re: Bottom End

Post by Tedh98 »

What forced you to rebuild the bottom end?
1Kam
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Re: Bottom End

Post by 1Kam »

My Oil Was concrete looking & my Kicklever Locked up
sarrant
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Re: Bottom End

Post by sarrant »

Concrete looking oil: You mean, transmission oil?

Because the bottom end is oiled by premix fuel.
1Kam
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Re: Bottom End

Post by 1Kam »

lol I guess This is My First KDX & someone said It Might Be my Bottom end But I believe my Pistons are Seized
pumpguy
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Bottom End

Post by pumpguy »

Could be lots of problems.

An easy way to see if problem is bottom end is to see if the crankshaft will rotate.

One way to do this is to remove the flywheel cover and spark plug. Then put the transmission in neutral and try to rotate the flywheel by hand or with a wrench.

If you can't rotate the flywheel, then you most likely have a seized piston, or less likely bad big end or main bearings.

Good luck and let us know what you find.
sarrant
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Re: Bottom End

Post by sarrant »

To be clear: a seized piston would require a new top end, not bottom end.
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Tedh98
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Re: Bottom End

Post by Tedh98 »

1Kam - I think it would be helpful to provide some more background on what is happening with your KDX.
1Kam
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Re: Bottom End

Post by 1Kam »

It was running good , until I cut it off and let it sit for an hour and once I tried to start it back up the Kicklever moved twice then after that I wouldn't move anymore
sarrant
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Bottom End

Post by sarrant »

Well, there may be a couple of things going on here.

If you've never taken the top end off, now's probably the time. Even if the problem is not in the engine (it is in that cementy-looking transmission case), now would be a good time to inspect the top end and see if it needs refreshing. Once you have the top end off, you'll be able to identify where the problem is if in the engine (top or bottom).

As for the oil that looks like cement: Is it watery/frothy, or is there a lot of metal in it?
If it is watery, your water pump seal has probably gone, and perhaps there was an overheating issue that lead to seizure. If it is metallic, perhaps something has broken loose in the cases and that is what is locking the kickstarter.

There is more than one possibility here, and you are going to need to investigate further before you have enough info to identify the problem.
Last edited by sarrant on 03:28 pm Apr 14 2016, edited 1 time in total.
1Kam
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Re: Bottom End

Post by 1Kam »

Thanks , I'll Let Everyone know what's going on once I Find out myself .
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