1980 Kawasaki KDX80 back to life

Joined
Mar 25, 2021
Messages
21
Likes
8
#32
KDX #2 update:
I noticed a leak coming from the case – I don’t like leaks, so let’s figure this out. It seems to be coming from the plastic magneto housing – but there is no oil behind there – odd – closer inspection reveals it is coming from one of the bolt holes that hold the plastic cover on. Back up a bit – when I took this thing apart I remember a noticeable amount of red high-temp silicone on one of the screws for the magneto, I didn’t think anything about it as these old things have silicone everywhere, I just figured it was part of a gasket (that was missing of course). So more silicone it is – that plugs that leak but was curious as to why it would leak there.

Fast forward to a ride around the block – I know that sound as the bike comes to a halt – no compression. Crap. I have compression – at least on the top end as that’s all new. I have spark and gas so it has to be a crank seal or the mating surface for the crankcase. Is it related to that oil leak? OK, let’s take it apart, that way I can figure out what’s going on with that leak.

I F**ed up as the seal on the right case for the crankshaft is, well, messed up. Must have been upon assembly, from the outside the seal looked perfect but somehow the little coil thingy got smashed. I will assemble the case and THEN install the seal this time.

Now let’s figure out that leak – so you can see in the photos there is a small hole. There isn’t supposed to be a small hole. That’s the bottom of the screw hole for the magneto cover. Was it like that from the factory? Did someone try to tap it deeper and run the tap through? One will never know. That will get welded up for a sure fix. It’ll be a couple of weeks before up and running so a final (I hope) update at that time.

case_1_s.jpg

case_2_s.jpg
 

RM_guy

Moderator /
Damn Yankees
Joined
Nov 21, 2000
Messages
6,806
Likes
312
#33
Nice investigating work there!
 
Joined
Mar 25, 2021
Messages
21
Likes
8
#34
So that should wrap this up - a couple mile test ride and everything seems to be in order, now to just find the next project...
done-again_1_s.jpg

done_again_2_s.jpg