KDX200 Engine Tear Down: You'll NEVER Guess What Happens Next!

Tearing down the KDX engine to replace crank seals, surprise found! Hopefully, i'll be able to remove that broken bolt pretty easily.
Stay tuned for another exciting episode of wrenching on vintage dirt bikes!

[@GermyBallswell]

I kept this video in mind while buttoning up my kips on my 1990 restoration. Mine also is sleeved. Everything moved smoothly but i was waiting for a new wave washer ( 92022-1978 ) when i installed the wave washer it added a ton of friction. I guess they come really wavy and i squished it, which solved it. However since yours is stuck without the wave washer i kept checking what it could be. And i noticed the large bel part of the center exhaust valve very very slightly rubs against the outside of the cylinder sleeve. For mine its not enough to bind it. But if it was machined slightly different or my sleeve was thicker it would certainly bind. Maybe you can dremel that spot alottle to give the valve dome more clearance.

[@XXXCRSPL]

I'm in the process of rebuilding my 96 KDX 200 had to send the cylinder out for replating and crankshaft rebuilt and about to put it back together

[@sandysmith7485]

You can get a flywheel puller at any auto store for 20-25 bucks. They work fine. I'll try to find your FB post about the fly wheel weight and send you a pic. Ride safe my 2 wheel friends.

[@ShaunSavage-kl9pd]

Nice I've got a cr250 but ride woods off-road. Might get a kdx200 or kx500

[@GasSoakedRag]

KDX all the way

[@zando_]

If that's the bolt that holds the flywheel on, it should remove easily with one of the bolt extractor kits. I had the same bolt shear on my dad's KL650 (right at 145ft-lbs torque, which is what the manual calls for) when I was working on it, he was able to extract it pretty easily. As there's no tension on the threads once the head is snapped off, it doesn't remain as stuck as I thought it would.

[@GasSoakedRag]

It is! That's good to hear.

[@XXXCRSPL]

Ya your missing the threaded part of the crank shaft and the woodruff key checked out

[@GasSoakedRag]

I'll be posting an update in a day or two.

[@dougk6693]

Your cylinder should NOT have cross hatching in it!!! It should be a coated cylinder. You have just aluminum bore with a little bit of coating left!

[@GasSoakedRag]

It's a steel lined cylinder.