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frontline510

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About frontline510

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  1. Hi everyone. The bike in question is a 1990 KDX 200. I recently replaced a broken exhaust valve and repacked the muffler. Upon reassembly I have discovered an extra bolt/nut. The bolt is about and inch and a half and has a 1/2" head and 1/2" nut . I have went over everything again and again and cannot seem to find out where it is from. I removed the tank, right side fairing, entire exhaust pipe, cylinder head, cylinder, and the power valves. The only bolts I remember being this size were the engine bracket bolts which are all accounted for. Any help would be appreciated. Thanks.
  2. frontline510

    1990 KDX 200 Gearbox Oil Issues

    What I was questioning was whether it is possible that air filter is sucking on the overflow hose.. The hose sits on top of the air filter. Either way I really don't think it belongs in the airbox. To change the tranny oil I rode the bike for 5-10 min to warm up and circulate the oil. I drain from the drain plug underneath. I let it sit until it stops dripping, then move the bike around to get more out until it stops. Put the plug back in. I start filling with approximately .7L (the manual calls for .8) Then I level the bike and check the sight glass and add very slowly until it reaches halfway up the glass.
  3. frontline510

    1990 KDX 200 Gearbox Oil Issues

    The coolant level in the radiator and overflow container have never dropped. The coolant looks new. I just changed the gearbox oil today. I took it out for a 30 min ride. Same leak from the overflow. You may be on to something about the vacuum affect. Tomorrow I will clean out my airbox (again) and try pulling the overflow hose out of the air box. I will zip tie the hose elsewhere and plug the hole in the air box. Thanks for the advice.
  4. frontline510

    1990 KDX 200 Gearbox Oil Issues

    I recently acquired a 1990 KDX200. The bike runs reasonably well for it's age. The first ride over 30 min the gearbox oil started overflowing into the airbox (overflow hose is routed to airbox). The oil that overflowed and the oil in the gearbox are an odd shade of dark forest green. The oil appeared to be overfilled slightly which explains the overflow. What I don't understand is the weird dark blueish greenish gray color of the oil. I believe the PO used motul 10w40 ester gearbox oil because he gave me a half used gallon. I use Motul 710 2t oil which is blue, and run green coolant in the radiator. I drained the gearbox oil and there was a nice little clump of dark gray metalic paste on the magnetic drain plug, which should explain the gray hue. What I do not understand is the greenish blue hue. Anyone know what in the heck is going on with this old horse? The pic shows a sample of my drained oil. When held up to the light it turns more of a green color. Oil still feels slick as can be.
  5. frontline510

    Mid pipe exhaust leak 2001 Wr250f

    Solved. I used most of a soda can to make a gasket. I cut the top and bottom off of the can, leaving an aluminum sleeve. I then cut the sleeve open so I can wrap it tightly around the header/muffle joint. Then I slowly pressed the muffler pipe over the aluminum sleeve wrapped joint. It was a little too tight of a fit to fully seat the two pipes, so I took a rubber mallet and whacked the back end of the muffler until it seated all the way. No more exhaust leak. Thanks for the help guys.
  6. frontline510

    Mid pipe exhaust leak 2001 Wr250f

    I've already tried using high temp gasket maker. It blew out the first ride. As suggested i tried using soda can strips which got rid of 90% of the leak. I am going to try a combination of the soda can and gasket maker today to see if I can completely fix the leak. I'll let you guys know how it turns out.
  7. frontline510

    Mid pipe exhaust leak 2001 Wr250f

    This is not the original pipe. The white bros muffler is not slotted and flanged like the stock one in the pic. When I took off the exhaust I do not recall seeing a gasket or clamp where the two pipes meet. I have already searched my work space and parts bin extensively and found nothing. Anyone got any suggestions?
  8. frontline510

    *Post Your Kawasaki 2 Stroke Pics Here*

    1988 Kx250 & 1990 KDX200 (1972 Yamaha DT2 & 1988 Kx250) All three of these bikes ran like champs last week in Tahoe.
  9. I just recently re-installed my White Bros exhaust system on my 2001 Wr250f. It's a two piece (header and muffler). I installed the header, then slipped on the muffler. The muffler fit very loose around the header where they meet. I tried angling the header and muffler at all different angles, yet still very loose. So I went ahead and used some high temp gasket maker, which failed the first ride. Am I missing a gasket or spacer of some sort? If I push the muffler into the header and extra 1/4 inch it fits air tight, but then I cannot bolt the muffler into the mounting brackets. Any help or suggestions would be greatly appreciated. Thanks.
  10. frontline510

    All 3 Intake valves have zero clearance! Help!

    The intake buckets cannot be removed because the camshaft recess has been damaged. There is a metal lip hanging over top of the intake buckets preventing them from coming out.
  11. frontline510

    All 3 Intake valves have zero clearance! Help!

    What's happened is the cam journal bore of the head has be smashed by the camshaft. The journal bore has mushroomed over the bore of the cam buckets, creating a lip. This lip prevents the buckets from being removed, and also seats the cams deeper than spec. I think this is why there was zero clearance.
  12. frontline510

    All 3 Intake valves have zero clearance! Help!

    I actually meant .15mm
  13. frontline510

    All 3 Intake valves have zero clearance! Help!

    I have discovered what my problem is. The cam journal bore is badly damaged. The valve buckets are stuck because a lip has formed over them from the damaged cam journal bore. I wonder how this happened? I remember when I removed the intake cam that it was almost seized to the cam journal. I guess I need a new head?
  14. frontline510

    All 3 Intake valves have zero clearance! Help!

    I have no idea when the bike was last serviced. I acquired it a few months ago and I'm trying to get it running right. I replaced the timing chain, guides, and piston rings. The valves did not get replaced. My question was what caused zero clearance in the valves. I did not ask for the definition of a complete rebuild, thanks.
  15. frontline510

    All 3 Intake valves have zero clearance! Help!

    Correction, only two of the intake valves have zero clearance. The intake valve closest to the cam sprocket has a clearance of .04mm, which is still extremely tight.
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