Messages

1

Kawasaki / Re: 87 KDX200 Help Needed

« on: April 02, 2020, 05:56:14 pm »

Sorry, should have mentioned that it is currently running a copper gasket that is bore size. Have not measured the compression, it just feels very high by my foot.

2

Kawasaki / Re: 87 KDX200 Help Needed

« on: April 02, 2020, 12:11:18 pm »

SOOO,

 The headgaskets i bought are not the copper type and are for a standard bore. Bit the bullet and pulled out the dremel, and took some material off the head, basically laid back the original step/ radius from the quench area to the combustion chamber into a smoother transition, not great but has dropped the compression a bit. Unless someone knows more about 2 stroke quench to bore ratios and is willing to share i am not going to go any further.

 Will Having high compression make the bike not want to idle? I have the idle screw all the way in and still cannot get the  ###ing thing to idle? I am currently running a #42 Pilot in the carb would that be too lean?

3

Kawasaki / Re: 87 KDX200 Help Needed

« on: March 28, 2020, 08:13:14 am »

 OK so a genuine PWK was fitted and already have an improvement in idle quality. Will be fitting an extra head gasket and then on with the jetting saga.

4

Kawasaki / Re: 87 KDX200 Help Needed

« on: March 23, 2020, 10:12:22 am »

Thanks guys,

 TT5 Matt i had the plug out and she turns over freely, when i was assembling i did check i had clearance, i was a little cautious of that as i already had to take a couple of mm of the bottom of the piston skirt to clear the cases, have ordered another head gasket to drop the compression, but i think the long term solution will be to get the head machined to suit
 
 Have also ordered a genuine PWK to see if that sorts out the jetting issues, it currently runs very rich at idle which i have tried to fix by going smaller on the pilot (air screw seems to do nothing) but now have it running very lean once on the pilot. I am not sure if that is a symptom of the high compression or the junk Chinese carby.

 Will keep you posted on results

5

Kawasaki / Re: 87 KDX200 Help Needed

« on: March 19, 2020, 01:50:55 pm »

Cheers,

 Was a little concerned, only way to get it to start is to get towed and even then is locking up until i get it in 6th. Still yet to sort out the jetting properly it is currently very rich.The original carb was trash and for now have a fake air striker 35 on it so pretty much starting from nowhere (not quite have changed the jets to 88 specs which had a 35mm kiehin flat slide).

 As for the compression it feels distinctly harder to kick over than a mates TM300.

if anyone has a good/ replatable air cooled KDX cylinder give me a yell, not entirely keen on the big bore thing

6

Kawasaki / 87 KDX200 Help Needed

« on: March 18, 2020, 12:17:40 pm »

Morning gents,

 Have nearly finished the build up of my old KDX200, when i purchased this old girl someone had previously bored and sleeved the barrel for a 240 kit, there is no evidence of the head being modified in any way to suit this. My question is could this cause the compression to be to excessive to run properly/ start easily.

 in the long run i would prefer to go back to the standard plated barrel however the budget is not there at the moment

7

Yamaha / Re: it465h rebuild

« on: April 18, 2018, 12:05:00 pm »

Hi Guys,

Bit of a thread dig as progress has slowed on the old girl significantly.

 I am currently relacing the rims and converting the rear to 18" (sacrilege i know but i intend her to be a rider, keeping all the old spokes and rim etc). Since i have gone this far i believe i should repaint the hubs and headstock.

 Can anybody recommend a good paint match for these parts or do i just go ahead and paint them the same Blue i was going to paint the frame (or yellow?)

8

Yamaha / Re: TT350 disc rear brake conversion

« on: July 29, 2017, 02:37:14 pm »

I had good luck using a DT200R rear wheel, caliper and mount plus the dt200R brake line. All lined up really well only had to machine down the TT sprocket side spacer by a few mm (not sure how much now been a while). Welded an extension off the back of the existing brake pedal and mounted a YZ426/450 11mm rear master cylinder off the back of the subframe rail (conventional location). The TT sprocket bolts straight up. You will have to shorten the drum brake locating stud (shaft?, sticky outy thing?) but the whole setup could be easily retrofitted back to drum rear brake if required.
 This setup has worked quite well for me after mucking about with various master cylinders i now have good pedal feel and travel.
 Pictures would help i know but i am working away from home and will not be back until next week, i also have no idea how to put photo's up now that PB has gone.
 PM me with a number later in the week and i will txt you some photo's when i am home 

9

General Discussion / Re: Carburettor Diaphram Repair

« on: June 13, 2017, 04:29:27 pm »

Have had luck using blue rtv silicon as a temporary repair, lasted 6 months and still fine when new one installed. Was only a small 3mm tear though. Could still get a new one for my 350 2 year's ago

10

Yamaha / Re: TT250 / TT350 Rear Spring Rate

« on: June 03, 2017, 06:30:19 pm »

The 250 and 350 shock is the same. Had shock treatment rebuild mine with new spring and damping to suit my weight and could not be happier with it. Well worth every cent.

11

Yamaha / Re: it465h rebuild

« on: May 30, 2017, 06:49:03 pm »

Well figured i should add some updates to this thread, the cases are currently away getting welded up and i hopefully should have them back in a couple of weeks thanks again Bell Moto for the advice.

 Also thanks to the very generous assistance of XL59 i now have a replacement 5th gear.
 
Now onto the frame, it looks like the swingarm bolt has been seized in at some point in the bikes life

http://i1244.photobucket.com/albums/gg575/Tomthesparky/WP_20170528_001_zpsjljunw29.jpg

And when they hammered it out the frame ended up a little tweaked as a result. Any advice on the measurements from the string line which is running from the centre of the spine tube to the centre of the bottom cross rail? or should they just be equal?

 Also stripped off the tire on the front rim and found this little suprise

http://i1244.photobucket.com/albums/gg575/Tomthesparky/WP_20170528_002_zpseygorwer.jpg

 So will be getting a new front rim Since i am already doing the front is it worth upgrading to an 18" on the back? keeps it all matching i guess

12

Yamaha / Re: it465h rebuild

« on: April 27, 2017, 06:56:20 pm »

Thanks to Bell Moto and Lozza for their reply's on repairing the damaged cases in the tech section, will be getting them in to be repaired as soon as i can get the time to drop them off.



Figured if i could get a rigid flat surface to bolt the cases to i could minimize the chance of warping



That should do the trick i hope



And no i did not drill the holes they are a witness to previous peoples attempt at "repair" using epoxy and wire by the looks of it.

Anyone out there know of good replacement sections for IT465 pipes? The lower section on this one is held together by muffler bandage and hope.

13

Yamaha / Re: it465h rebuild

« on: April 26, 2017, 08:20:39 pm »

As promised a picture of the start of the project, not really sure if i can re-use the old plastics, apart from the tank and the RHS sidecover nothing else is restorable.

Begin by stripping the head and barrel off (no Photos) piston is 1mm O/S however measurement of the bore shows it is undersize for that, thinking some tightwad bored it for a used piston.

Onward to splitting the cases
Crank seems good, main bearings have no markings and appear to have areas where the seals have been removed, definitely not C3 these will be tossed, gearbox bearings seem ok except for the selector drum bearing which is tight from sitting in water in the crankcase, think i will toss the lot to be sure.
 Gearbox looks good except for 5th pinion
 Not sure what happened here as the output shaft gears are all good.

 That should be enough for now, more progress to come (slowly)

14

Yamaha / it465h rebuild

« on: April 24, 2017, 12:48:14 pm »

Hi all,
 
Thanks for having me, now time to pick some brains about this old monster. Bought it recently and she is a bit rough but complete, looking at bringing her back to her former glory. This will not be a showroom piece nor a complete original, just a good rider. Plans so far are repair the frame loop, the cracked crankcase, plus replace a 5th gear and freshen up the motor.
 realise thus is useless without photos and will post some as soon as i figure it out

15

Tech Talk / crankcase repair maitland area

« on: April 17, 2017, 08:25:04 am »

Hi all,
 have a set of IT465 cases and they are cracked/broken at the kickstart area, have all the pieces. Was after any recommendations for someone in the Maitland or Newcastle area who could weld them up