Jump to content

canucklehead2004

Members
  • Content Count

    109
  • Joined

  • Last visited

About canucklehead2004

  • Rank
    TT Bronze Member

Profile Information

  • Gender
    Male
  • Location
    British Columbia
  • Interests
    ATVing, hockey, curling
  1. canucklehead2004

    89 KDX 200 torque specs. front end

    thanks very much for that. they are the T1s = 14.5 ft lbs. I went 18 or 20 so I think I should still be okay.
  2. canucklehead2004

    89 KDX 200 torque specs. front end

    Just had my fork seals replaced. What do I torque the triple tree bolts to? they are a 12mm socket bolt. what do i torque the front axle/wheel nut to? It is a 19mm bolt. Thanks!!
  3. canucklehead2004

    300 exc hard cold start

    "50" is what I read on it (I think it was marked on the end where the screw slot is located). It is a 1996 model bike/carb, and I put a 1999 motor in it. Not sure if that means anything. Once started and running, it's great. re-start is also fine once warmed up.
  4. canucklehead2004

    300 exc hard cold start

    I did clean it when I cleaned carb. It didn't seem to have any blockage when I cleaned it. only high idles with choke on, then settles down. plus idle adjusts properly (I can get it to idle higher or lower). thanks for the reply.
  5. canucklehead2004

    300 exc hard cold start

    it takes 10-12 kicks cold, maybe more, full choke. new piston, good cylinder. new plug. cleaned carb and I have a 50 pilot jet. if my son tries to start takes longer as he tends to rabbit kick whereas I am steady/full kick. I get no burb, nothing, and then all of a sudden it fires right up and idles high on choke. I can shut choke off right away once it starts. Is this normal? what can I do? I'd like 1st or 2nd kick like my 1989 Kawi KDX 200.
  6. canucklehead2004

    99 exc 300 kick start broken, and hard cold start

    did you pay attention to which way the kickstart pedal spacer was facing? i'd only order the small pawl spring & pawl. did you press out the pin? Don't waste your time trying a punch or hammer, you'll only bust something. I used a 1/4" socket and a chain press tool. AND AN UPDATE....... that power valve rod was bent and I replaced it.
  7. canucklehead2004

    99 exc 300 kick start broken, and hard cold start

    finally got all the parts. there are several confusing things about re-assembly, and time elapsed since disassembly doesn't help. anyways, i think I got most of it, but am wondering about the spacer between the kickstart pedal and case seal. Does the bevel/cone end on spacer go towards the seal side? or up against the kickstart pedal side? looks like the cone has been against the pedal based on markings to pedal. On the parts diagram, looks like the cone should go against seal side. I thought cone on seal might wear seal??? this was not an easy job, not sure why people call this simple. Had to press out the pin holding broken pawl on there, and yo ubetter have some tooling and imagination to do that. That was a PITA. the shim washer behind kickstart shaft is easy to miss or forget. same for the washer between the clutch baskets. lining up kickstart shaft is tricky, (manual made it confusing), and then making sure you set big spring correctly and tension it right aswell was tricky/confusing. I can see lots of areas where I could make mistakes (usually if something can go backwards... I find a way to do it. must be cuz I'm lefthanded). still hard to cold start. takes 10 or so kicks. After warmed up, takes 3 kicks. It's like I have to find compression to get fire. Also seems like I've shortened the length of kick stroke (or maybe not and I'm just paranoid). I also replaced the smaller pawl spring and am glad I did. old one was shorter, probably worn and compressed. I replaced the outer/bigger spring and driven hub and the lock tab washer. I don't think I needed to do any of those. nor the pawl pin (but i did anyways).
  8. canucklehead2004

    99 exc 300 kick start broken, and hard cold start

    good info, thanks. any idea what the clutch basket nut is supposed to be torqued to?
  9. canucklehead2004

    power valve rod bent? is this hole in my case normal?

    any connection to that hole and cold start problem? yeah, with fluid level not changing...makes me wonder. So I could probably run it into the ground as is because I've got nothing to lose. cases are line bored together aren't they, so they both have to be replaced? can hole be patched somehow? and if hole isn't supposed to be there, where did the missing chunk go? I noticed the clutch cover gasket is pretty new, so maybe previous owner knew this aswell?
  10. canucklehead2004

    power valve rod bent? is this hole in my case normal?

    with fluid spinning around in there I would have expected it to drain my clutch area and fill fluid somewhere it shouldn't go. my clutch fluid level was perfect. another broken POS I own? any idea on the power valve connecting rod angle?
  11. canucklehead2004

    power valve rod bent? is this hole in my case normal?

    looks more like an intake area. my thumb could fit in there. I did a google image search for ktm 300 case and saw a 96 that looked similar. how could it run like this? it ran good, i shut it off. then my kick start was ratcheting so I couldn't re-start it. I pulled clutch cover off and saw this. Both pieces of broken pawl from the kickstarter were found easily.
  12. I just removed my clutch cover to repair kickstarter on my 99 300 EXC. is this curvature/angle/bend on power valve rod normal? Upon removing clutch cover i also saw this hole in my case. is this normal?
  13. canucklehead2004

    99 exc 300 kick start broken, and hard cold start

    here are the pics: Is this hole in the case normal? Is this plastic "driving hub" normal, or should i replace. not sure if you can see the warp Is this rod bent, or is it normal curvature? can I re-use this washer on the clutch basket nut? I would bend the tab that hasn't been bent yet. i thought it might be designed that way so you get 2 uses out of it. this is the broken pawl: and these are the pawl chunks I located:
  14. canucklehead2004

    99 exc 300 kick start broken, and hard cold start

    forgot to mention... ANYONE who is reading this and hasn't done this job.... it is CRITICAL to locate your broken pieces. I strained my oil to find the 2 chunks of the broken pawl. seems like pawl is weak in that spot and might break again (i guess another 12-14 years). if you ignore locating broken chunks they could grenade around inside there and really chew up some damage.
  15. canucklehead2004

    99 exc 300 kick start broken, and hard cold start

    yeah, it is a PITA.you have to dig pretty deep to get to it. I was smart enough to leave the water pump cover in place, but never removed fat pipe or the upper power valve cover (at first). I noticed the clutch cover was tight to pull off, and then realized I had to disconnect the power valve connecting rod. I did not wrestle the cover hard, but I noticed the power valve rod has an angle to it, like a 22.5 degree bend. Is that normal or did I bend it? the metal is pretty strong and i never twisted or bent it hard; I felt resistance, stopped and removed more stuff. yep, the pawl is broken. I also noticed the plastic "driving hub" is a bit wavy/bent where the big spring pokes through the hole, probably from the tension of the spring. Should I replace that plastic hub or is it that critical? I expect the new one would get a similar wave/bend from the spring tension. And what about the springs (the pawl spring, and the big spring)? leave it? replace? the pawl and needle are $20. I noticed one other thing.... there is an odd shaped hole in the right side case. I took pics and will post. Wondering if it's normal, or if mine somehow broke. It was running perfect before this kickstarter issue. Clutch nut spun off super easy with an impact. Can I re-use the locking tab for the clutch basket nut? only one tab was bent, and I see a second tab. I could bend the second tab and leave the other one straightened out. I'll post a pic of that too.
×