Author Topic: 89 KDX200F  (Read 25871 times)

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Offline Mick D

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #30 on: July 20, 2016, 10:29:21 pm »
The dregs of your morning coffee brew :P

The remains of the Japanese guy that set the timing at the factory :o

The content of the 2T oil tank that keeps emptying by itself ???

Possibly a crank seal gone ;)

Yes, all of the above ;D

No, I reckon it started as 2T oil once.
Yes siphoned through the pump whilst laid up, straight into the crank cases.
I will add there is absolutely no Radial or transverse wear or play in crank bearings.
So Maybe there was a built up of crank case pressure while it was running trying to clear. Given it takes along time to clear itself.
Maybe that helped fail the LH ignition/Crank seal Prematurely?

But I really think that this problem started long ago in this bike.

I washed the cover out ready to knock up a gasket.
Went to blow out ::) ::) :o
Instantly got covered in black oooze fleckles ;D ;D ;D ;D ::) ::) ::) ::) ::)

bArrrh,,,, so I notice its got some sort of a tin shield inside the cover and that the black shit had sprayed out from behind it(when I hit it with the air).

« Last Edit: July 20, 2016, 11:37:08 pm by Mick D »
"light weight, and it works great"  :)

Offline Mick D

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #31 on: July 20, 2016, 10:51:07 pm »
No I beg to differ on that one.
I have seen a lot of globes blow from high voltage, they break the filament.
Only a current surge blows the filament clean of both post mounts in every globe, with out exception.
That feed circuit to all the globes surged the moment the Rect/reg which is connected to the same circuit and back to earth failed and open circuited. Thereby allowing the full unrectified and unregulated now AC output of the Alternator to surge straight through every globe that was closed circut.

There are two highly accredited light aircraft constructors who agree with me too, but more on that later if you like.
But yes add that to yet another piss pooor cheaped out Kawasaki inadequate design by not having a capacitor in the system to smooth out the spikes.

"light weight, and it works great"  :)

Offline Mick D

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #32 on: July 20, 2016, 11:05:33 pm »
So, behind that tin plate mounted on the inside of the stator cover there is another part!
A lining of what may have been some sort of rubbery material to start with?

That the 2T oil has decomposed?


So no, that wont be going back in ::)
I wonder why it was there in the first place?

As a acoustic barrier to help achieve a desired DB rating?
To comply as the international registrable SR model ?
Sad thing is all acoustic insulators also have a value as thermal insulators, keeping heat in a place where you most want to get rid of it. Better ways to do this Mr Kawasaki.
« Last Edit: July 20, 2016, 11:48:58 pm by Mick D »
"light weight, and it works great"  :)

Offline Mick D

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #33 on: July 20, 2016, 11:09:46 pm »
So this is what is left of the stator that measures differently when hot as opposed to its cold measurement


This isn't a cheap bike anymore ???
"light weight, and it works great"  :)

Offline Nathan S

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #34 on: July 21, 2016, 10:23:05 am »
All the F models have that black greasy shit under the ignition cover. It's always foul - like moly grease mixed with old sump oil.
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Offline FourstrokeForever

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #35 on: July 21, 2016, 10:47:22 am »
I wonder if all the knockers of your XR500 will change their minds now MickD  ??? ::)

With regards to your regulator/rectifier system, there are "battery eliminators" on ebay. They can only be a capacitor so maybe that could be a cheap fix for the electrical woes caused by the even cheaper resistor.

I'm also with you on removing the oil injection.....It's only something else that can, and obviously does, go wrong. There's nothing hard about carrying around a small (100ml) plastic bottle filled with some 2t oil wrapped in a plastic bag stashed in your back pack. (I assume you take water and tools with you on trail rides 'cos you don't strike me as a silly bugger)   
Arrogance.....A way of life for the those that having nothing further to learn.

Offline Nathan S

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #36 on: July 21, 2016, 10:58:36 am »
I'm not gonna change my mind on XR500s, but I'm gonna offer Mick $100 for his KDX... :D
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Offline Lozza

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #37 on: July 21, 2016, 01:36:48 pm »
So anyhow, I start testing the electrics to track down cause of surge.

What no capacitor on alternator feed to smooth out current spikes, how disgustingly cheap MR KAWASAKI >:(
Considering the amount of unnecessary crap you did add. Dick heads.

Checked ceramic resistor on Alternator feed back to earth, 5.8 ohms. I reckon that's probably about the only thing that's not $%%$#@@$

Diode check on Rectifier/Reg, yeap she's %^^%$#@#$

Sorry, no longer available. Could wire in any one I suppose. But I found the OEM one freshly listed on ebay that night.


Any 2 phase rec/reg will work $8 pit bike ebay specials work a charm. Capacitor can't work on AC only DC which has to on the output side of the rec/reg. CR250's and some XR's have a rec/reg and cap already usually $30 on ebay USA or $6 from Jaycar for a 2200uf  capacitor
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HeavenVMX

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #38 on: July 21, 2016, 01:51:03 pm »
No I beg to differ on that one.
I have seen a lot of globes blow from high voltage, they break the filament.
Only a current surge blows the filament clean of both post mounts in every globe, with out exception.
That feed circuit to all the globes surged the moment the Rect/reg which is connected to the same circuit and back to earth failed and open circuited . Thereby allowing the full unrectified and unregulated now AC output of the Alternator to surge straight through every globe that was closed circut.

There are two highly accredited light aircraft constructors who agree with me too, but more on that later if you like.
But yes add that to yet another piss pooor cheaped out Kawasaki inadequate design by not having a capacitor in the system to smooth out the spikes.
Electrical Engineer Mick - maybe a quick read of basic AC theory would help. Anyway have it your own way the imaginary demon of a current surge. Possibly consider

I(current) = E (voltage RMS for an AC circuit) / (Z(R for resistance in this case) x Cos 'Phi")(in this case a value of 1 as it is a resistor circuit).

The variable that changes in an uncontrolled manor once the reg fails is the voltage which changes in both magnitude and frequency and is the root cause of the problem. Yes it results in a high current flow that has also, naturally, becomes an AC current in phase with the voltage but this is a consequence of the voltage problem not a cause.

Any electrical component such as a globe or any connection for that matter when exposed to rapid voltage transients as experienced when AC (remember that the AC frequency of a magneto is directly related to RPM) is supplied to a circuit designed for DC even if crude DC are severely stressed. They invariably fail at a high stress point such as at a connection (post in a globe) as the voltage peaks and transients far exceed design. High current tends to over heat the component causing breakdown of the material not a clean fracture.

The funny flip side to this is that DC currents are much harder to switch than AC current.

Having said all that I am sure you are right that current surges just happen spontaneously, much the same as spontaneous human combustion. Anyway I am not really interested in debating it further but feel free to rebuke my points.

I will give you $200 for the KDX which is double that offered by Nathan. It is obviously a POS all round anyway so maybe I can use it as an example of Japanese folly
« Last Edit: July 21, 2016, 01:53:14 pm by HeavenVMX »

Offline Mick D

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #39 on: July 21, 2016, 03:23:15 pm »
Thanks guys, I do appreciate the knowledge etc. It will be a good fun thing with a bit more work.
Talking about learning etc. Just got back from Sydney with this
http://www.ebay.com.au/itm/Bench-Lathe-Hafco-AL-320G-/162132675013?hash=item25bfdc49c5%3Ag%3AwQIAAOSw0kNXgwdX&nma=true&si=UDIvFsEhKl4qSp7%252BYq2R4gBGTWM%253D&orig_cvip=true&rt=nc&_trksid=p2047675.l2557

I didn't think too many could teach me much more about machining, but this old retiring, going into a unit bloke sure did  :)
What a great moment in my life meeting him.
Then he turned around and gave me thousands of dollars worth of new condition tools, books etc, etc.
What a day, it could be only more perfect if I could take the KDX for a squirt,,,soon Grasshoper soon :)
« Last Edit: July 21, 2016, 03:24:52 pm by Mick D »
"light weight, and it works great"  :)

Offline Mick D

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #40 on: July 21, 2016, 03:29:37 pm »
I wonder if all the knockers of your XR500 will change their minds now MickD  ??? ::)

With regards to your regulator/rectifier system, there are "battery eliminators" on ebay. They can only be a capacitor so maybe that could be a cheap fix for the electrical woes caused by the even cheaper resistor.

I'm also with you on removing the oil injection.....It's only something else that can, and obviously does, go wrong. There's nothing hard about carrying around a small (100ml) plastic bottle filled with some 2t oil wrapped in a plastic bag stashed in your back pack. (I assume you take water and tools with you on trail rides 'cos you don't strike me as a silly bugger)

Yes, on all accounts Mark  ;D :)
Ironic that the XRs have a capacitor as standard and the new layout will basically be a transplant of the Honda schematic to bring to the KDX up to spec with what it should off had to start with.
"light weight, and it works great"  :)

Offline 80-85 husky

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Re: Disgusted with 1989 KDX200 poor oil pump concept and design
« Reply #41 on: July 21, 2016, 10:15:37 pm »
mate bought one of them kwakas for his son to learn to ride. I got to take it out for a spin with the boyz. it got me up every hill first time. and I had a crack at the "too steep for us" hills and conquered two out of three. men were not happy. ktm 450 / husaberg 450 and a kato 525 and a 300 twoi. the 200 put em to shame. ....and it was a dog...needed serious exhaust and jetting work to get some real hp out. but just flog the crap out of it and tap dance on the stirring stick and it went places. great little 200 twoi

Offline Mick D

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Re: Mick's 89 KDX200 Saga
« Reply #42 on: July 23, 2016, 06:52:06 am »
Well you'll have to dig deeper boys, received another bid via PM.
We are up to  $210 now  :)
"light weight, and it works great"  :)

Offline 80-85 husky

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Re: Mick's 89 KDX200 Saga
« Reply #43 on: July 23, 2016, 08:15:56 am »
clamp the oil hoses and run 40 to 1...use that castor blend, it smells great.

Offline Mick D

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Re: 89 KDX200F
« Reply #44 on: July 24, 2016, 06:55:35 pm »
So this is all you have to do to replace an ignition crank seal.
Only dismantle the entire bike, and then an entire engine rebuild /overhaul.
They should have bombed the joint to abblitoration.
Narrh glad they didn't. There would be no XRs then.
I should have taken the $210. Expensive reef awnament.
No need to wunder why they don't make them any more.
POS design.
"light weight, and it works great"  :)