Pickin up a dirt bike

[crazycart]

Later tonight or tomorrow i will be picking up an old late 70's Kawasaki KD100 for pretty cheap (50$) its just missing the seat,gas tank,and the left side engine cover.It should be a fun little bike.Its a 5 speed manuel and makes a whopping 8.5 hp at 6500 rpm! I will get some pics up when i get her home.

 

[ironman]

you going to drop it into a new kart project

 

[crazycart]

Nah Im just gunna get it going and ride it. Itll make a good cheap trail bike.

 

[2or3wheels]

i remember seeing that wasnt it 75 on craigslist?

 

[crazycart]

Yeah it was,i offered him 50 cus a few things were missing but otherwise it shifts through the gears fine,good clutch,great brakes.I need a flywheel puller to get at the points theres no spark.

 

[oscaryu1]

You could get a solid state...

When taking apart a 2/3HP Briggs, I was advised to use a flywheel puller. However, I took them off with a few raps of a hammer... As long as you don't hit em that hard, it should be fine.

 

[crazycart]

The thing is, these engines are TOTALY diffferent from a briggs, its a rotary valve 2 stroke, you cannot change them to solid state unless your willing to dump hundreds of dollars to get something custom made for it.This flywheel is rusted on pretty good, and it will not come off with a hammer.I might just have to own up and buy a puller.....

 

[2or3wheels]

WHAT that thing is rotary?? werid it was missing seat or something right, let me know how it goes.

 

[crazycart]

It isnt a Rotary Engine such as the Wankel engines, it is Rotary valve,the carb is mounted on the right side of the engine next to the clutch where mounted to the crankshaft is a disc that opens the intake when it rotates around.Ive read that rotary valve is the most efficient type of 2 stroke intake system over piston port and reed valve.And yeah it is missing the seat and gas tank but i have some extra ones that could work.

 

[Russ2251]

Rotary disk valve invented by Kawasaki in late '60's I think. Better than piston ported induction.

 

[oscaryu1]

The thing is, these engines are TOTALY diffferent from a briggs, its a rotary valve 2 stroke, you cannot change them to solid state unless your willing to dump hundreds of dollars to get something custom made for it.This flywheel is rusted on pretty good, and it will not come off with a hammer.I might just have to own up and buy a puller.....

Ah... well I've only worked on 4 strokes

Still though, I'd try a bit of penetrating fluid and a few light raps with a hammer. If it's rusted that bad, you don't have much to lose ...

 

[crazycart]

Ive already tried that, its harder to get them off then you might think.

 

[Russ2251]

its harder to get them off then you might think.

Kawasaki did/does supply their own pullers specific to their engines. Different size engines= different pullers. A generic type puller may or may not work. Check with a local cycle shop. If you ask them...they may pull it for you. Don't risk trying to 'muscle' it off. If it breaks or distorts you may not be able to easily replace it.

 

[crazycart]

This is exactly why i did not want to pound on it with the hammer, and yes, i am getting a puller for that specific engine.

 

[2or3wheels]

good call when it will get really expensive to buy a flywheel for a thing that may not even work, did you do a compression test?

 

[crazycart]

FINALLY got some pics of the ol' beast.Shes got almost 150 lbs of compression.I got a puller and i have the flywheel off but im gunna need to order some new point,condensor,and coil.Also the hydraulic table its sitting on i picked upat checkers for 20$!! it was their last one and they normally are 200++
Hopefully you didnt see to much of my garage!!

 

[ironman]

cool new toy looks like it will be fun.

 

[crazycart]

Well,today my new points and condenser came,hooked them up and bam fired right up.She sounds real nice except the carb is gummed up bad so it doesnt idle good and i have to feather the throttle to get it up to high rpm,ill pick up some carb soak tomorrow and clean it out good.I did get it into 3rd down the road and its pretty dang fast for a 100.I also put on some PowerMadd handgaurds to make her look a bit better.Ill take some more pics soon.

 

[oscaryu1]

This is exactly why i did not want to pound on it with the hammer, and yes, i am getting a puller for that specific engine.

I meant pound the end of the crank while using a pry bar to get it off. Who's would actually pound a flywheel??

 

[crazycart]

Bottom line, these flywheels are pressed on, and 99.9% of the time,do not come off with just a pry bar and hammer.Just recently i had to remove a pulley off the shaft of a 5hp for my minibike,first tried hammer,then impact hammer,then i bought a puller,that STILL did not take it off,i ended up going through about 3 sawzall blades cutting it in half.It was rusted on BAD.