learning to rebuild, alot sooner than i am ready for.

[dank]

can somebody point me in the right direction to a link on how to do a top end rebuild on a kx100 with alot of pictures? my little sister froze her bike up solid on her second ride out with it. im also on my first bike so i have only the vague idea on how to do the rebuild, so help would be greatly appreciated.

 

[Gassey fan]

try www.gasgas.com-manuals-ec_shopmanual_06

 

[dank]

link will not open for me... but thanks!

 

[eff]

Just buy a shop manual for it or at least one of these.

http://www.themotorbookstore.com/kx80.html

 

[mountain thumper]

take out the plug and fill the jug full of oil, wait a week, drain it out and kick it with no plug for a while then put the plug back. its not the best advice(in fact it may be the worst), but it worked MANY times on our old(70ish) kawi 175

 

[dank]

im thinkin its a stuck piston or a ring that got messed up. im curious though, how would you drain the oil out? and what oil would you use? since it may be cheaper to get a new jug, your idea is rather intriguing, if only for discussion..

 

[stainlesscycle]

usually hot seizes can't be fixed with fluid in cylinder...

go to kawaski.com
click on
owner info->parts diagram->kx100 (or whatever it is)->cylinder/piston
that'll show you what's going on in there, so you'll have an idea of the parts.


the process is the same for every water cooled 2 stroke.
drain radiator
remove head
remove cylinder base nuts
pull cylinder off (if pv you'll need to unhook first)
put rag in crankcase cylinder mouth
remove circlips from piston pin
push piston pin out (proper tool helps..but socket will work)

once it's apart you will need to check - piston, rings, cylinder,small end bearing, pin, and big end bearing play. you also need to clearance new piston, rings, etc. you will probably need a book to get specs for cylinder wear/etc. if you hot seized, you'll probably need a rebore/new piston/rings/pin/bearing and circlip. it's easier and harder than it looks to do it right

you may get away with just honing the cylinder (if the damage is MINIMAL - don't forget that piston slides up and down 10000 times a minute) but if it seized i would not reuse piston/rings/pin/bearing or circlips....
overall you're talking between $100 and $300 in parts i would think. rebores are cheap (usually $25ish). pistons are cheap for kx100 i would think (under $100)....

any competent motorcycle shop could do the job in 2 hours or so (minus the rebore).

 

[dank]

thank you very much stainless. the guy who does my suspension work said he would be willing to help me out if i needed it so that came as a big relief. thanks for the run through, im going to start taking things apart in the next week so ill keep asking questions as the need arises. thanks all for the replies!

 

[Krasi]

http://www.youtube.com/watch?v=-FFIWtqU5Zc

http://tutorialtub.com/info/how-to-do-a-top-end-rebuild-on-a-2-stroke-motor

http://www.off-road.gr/article25.html

http://atv.off-road.com/atv/feature/quadbarts-guide-to-2stroke-rebuild-offroadcom-11822.html

http://scooter.wikia.com/wiki/Rebuilding_an_engine

 

[dank]

thank you very much

 

[dank]

alright so we started in on that kx 100, i did get the motor free and it looks like the rings caught on the exhaust ports, because we took the head off, and there are big gouges right about the exhaust ports, and there is scoring on the piston in the same area.is it going to be worth trying to bore or replate the cylinder, or find a new one?

 

[blitz11]

Photos?

I've used millennium tech for replates, and it's worked fine. my guess is that a used kx100 cylinder/top end will be pretty knackered. Millennium Tech can salvage what normally might look like a completely destroyed cylinder. It's probably your best bet.

Good luck.

blitz

 

[stainlesscycle]

what year kx100? - replate will cost much more than bore. is it a nikasil bore or steel? i've had good luck with us chrome for nikasil plating.

 

[dank]

sorry for not being spacific. its a 2004 kx100. i will try to remember to take pics once i have the cylinder off.(we only had time to do the head.) i was thinking of sending it to ron and having him help me decide if its worth sleeving or boring. and to the best of my knowledge its nikasil plated. the main thing im trying to avoid is buying a whole new cylinder, thats 300 bucks! ill post pics when we get the cylinder off.