Question about kawasaki KX 125 Motorcycles

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Installed new cylinder, piston and rings on my 03 kx80. I drove it around for a half a day and it quit. It acts like it will run but dies out. took the carb off and cleaned it and no signs of carb probs.

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  • rchapman24 May 11, 2010

    did you change the plug?

  • davejthomps May 11, 2010

    Did you run engine hard straight away or did you take it easy?

  • Bruce Hathcock May 11, 2010

    Did you run it to lean and it scored the clinder walls? try a compression test to see.

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When u put those new things on the motorcycle, u go easy with the motor, u shouldn't had driven it half day. Do a compression test. check your timing again, change your spark plug, was your timing chain properly tensioned

Posted on Jul 26, 2009

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1 Answer

Motorcycle is losing compression and noisy


if it is a water cooled engine the ring gap at the bottom of the cylinder should be around .010"
rings have to be installed the correct way up or the compression doesn't help push the rings against the cylinder walls for effective seal
piston skirts will touch the cylinder walls as the pressure pushes the piston to one side as it pushes the piston back down the cylinder
I have to ask did you put an old piston back in the new cylinder
was the new cylinder standard size or over size
what was the ring gap before you fitted them to the piston
did you use new rings or the old ones --maximum rin gap is .025"
rings don't wear in , just wear out
why did you replace the cylinder in the first place
was it because of low compression or taper wear
as silly as all this seams it is all very relevant to your question

Mar 11, 2016 | 2011 kawasaki KLX 250

2 Answers

Installed new piston rings and gas is getting inside oil


valve not closing is from a bent valve. Black soot is from over fuelling and incomplete combustion. Oily chamber is oil from the rings. It si possible that more than one valve is bent as it occurs from turning the engine over without letting of the rockers when adjusting the valve timing.

Nov 14, 2014 | 2001 Hyundai Accent

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Recently had my 2003 VW golf serviced (engine flush & oil change). It was running well before the service but on the way home after the service it began blowing white oily smoke everywhere. We took...


I had a similar experience with a 1970 Plymouth Duster, at 10 years old (1980) I flushed the engine and started running a little bit higher detergent oil and it also started smoking as you described,turned out with the engine as clean as it got the clearances of different internal oil retaining parts such as valve guides and piston rings were slightly bigger causing my engine to smoke,

Feb 02, 2014 | Cars & Trucks

1 Answer

Driving home last night from work, engine started to shake and run rough, drove it home and the car sounded like a missing cyl. took it around the corner to the mechanic and tested on computer found...


When testing the compression did you squirt a little oil in the cylinder? if the compression doesn't change then you have a burnt valve, if it does change you have a broken rings on the piston

Aug 25, 2011 | Ford Explorer Cars & Trucks

1 Answer

55 rancher-put new after market piston,ring and cylinder new sparkplug,cleaned carb,tried adjusting hi lo-new gas filter,new fuel line ,cleaned air filter-will start but on acelleration bogs and dies took...


I had a very similar problem with a stihl 029 farm boss.I did everything you did except I took it to a shop to do the piston and ring replacement. When I got it back the first time it would run for about two mins. then die.I fought it for a couple of weeks then took it back and expressed my displeasure. Then checked it all over and replaced piston and ring again and it runs great. They told me they could not get the right compression with the first one and thought the groove for the ring was cut to deep.I hope this is of some help to you. Thank you.

Mar 21, 2011 | Husqvarna 455 Rancher 555cc 35 hp 20"...

1 Answer

Can i put a 96 inch top end on my 2000 roadglide without doing anything with the botom end?


You can install 95 cubic inch pistons and cylinders without disassembling the lower cases. The trickiest part of the job is installing the pistons into the cylinders, it is difficult to get a ring compressor around the piston, and then lower the cylinder onto it. You'll need a narrow ring compressor that will separate to allow you to get it around the connecting rod to get it out of the way of the cylinder. I installed forged pistons, new cylinders and heads on an '01 Dyna a couple of years ago, the only part I had to farm out was pressing the new cams into the cam plate.

Dec 03, 2010 | Harley Davidson FLTR-FLTRI Road Glide...

1 Answer

The engine has blown. I need to replace it or change pistons and rings. How difficult is it to change pistons and rings?


It can be time consuming and the end result may not be desirable if you haven't done it before.
--- The following is just a sample of what to do once the engine is torn down: Pistons and Connecting Rods
  1. Before installing the piston/connecting rod assembly, oil the pistons, piston rings and the cylinder walls with light engine oil. Install connecting rod bolt protectors or rubber hose onto the connecting rod bolts/studs. Also perform the following:
    1. Select the proper ring set for the size cylinder bore.
    2. Position the ring in the bore in which it is going to be used.
    3. Push the ring down into the bore area where normal ring wear is not encountered.
    4. Use the head of the piston to position the ring in the bore so that the ring is square with the cylinder wall. Use caution to avoid damage to the ring or cylinder bore.
    5. Measure the gap between the ends of the ring with a feeler gauge. Ring gap in a worn cylinder is normally greater than specification. If the ring gap is greater than the specified limits, try an oversize ring set. Fig. 5: Checking the piston ring-to-ring groove side clearance using the ring and a feeler gauge tccs3923.gif

    6. Check the ring side clearance of the compression rings with a feeler gauge inserted between the ring and its lower land according to specification. The gauge should slide freely around the entire ring circumference without binding. Any wear that occurs will form a step at the inner portion of the lower land. If the lower lands have high steps, the piston should be replaced. Fig. 6: The notch on the side of the bearing cap matches the tang on the bearing insert tccs3917.gif

  2. Unless new pistons are installed, be sure to install the pistons in the cylinders from which they were removed. The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. If a connecting rod is ever transposed from one engine or cylinder to another, new bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number. The notch on the piston head goes toward the front of the engine.
  3. Install all of the rod bearing inserts into the rods and caps. Fig. 7: Most rings are marked to show which side of the ring should face up when installed to the piston tccs3222.gif

  4. Install the rings to the pistons. Install the oil control ring first, then the second compression ring and finally the top compression ring. Use a piston ring expander tool to aid in installation and to help reduce the chance of breakage. Fig. 8: Install the piston and rod assembly into the block using a ring compressor and the handle of a hammer tccs3914.gif

  5. Make sure the ring gaps are properly spaced around the circumference of the piston. Fit a piston ring compressor around the piston and slide the piston and connecting rod assembly down into the cylinder bore, pushing it in with the wooden hammer handle. Push the piston down until it is only slightly below the top of the cylinder bore. Guide the connecting rod onto the crankshaft bearing journal carefully, to avoid damaging the crankshaft.
  6. Check the bearing clearance of all the rod bearings, fitting them to the crankshaft bearing journals. Follow the procedure in the crankshaft installation above.
  7. After the bearings have been fitted, apply a light coating of assembly oil to the journals and bearings.
  8. Turn the crankshaft until the appropriate bearing journal is at the bottom of its stroke, then push the piston assembly all the way down until the connecting rod bearing seats on the crankshaft journal. Be careful not to allow the bearing cap screws to strike the crankshaft bearing journals and damage them.
  9. After the piston and connecting rod assemblies have been installed, check the connecting rod side clearance on each crankshaft journal.
  10. Prime and install the oil pump and the oil pump intake tube.
  11. Install the auxiliary/balance shaft(s)/assembly(ies).
OHV Engines CAMSHAFT, LIFTERS AND TIMING ASSEMBLY
  1. Install the camshaft.
  2. Install the lifters/followers into their bores.
  3. Install the timing gears/chain assembly.
CYLINDER HEAD(S)
  1. Install the cylinder head(s) using new gaskets.
  2. Assemble the rest of the valve train (pushrods and rocker arms and/or shafts).
OHC Engines CYLINDER HEAD(S)
  1. Install the cylinder head(s) using new gaskets.
  2. Install the timing sprockets/gears and the belt/chain assemblies.
Engine Covers and Components Install the timing cover(s) and oil pan. Refer to your notes and drawings made prior to disassembly and install all of the components that were removed. Install the engine into the vehicle. Engine Start-up and Break-in STARTING THE ENGINE Now that the engine is installed and every wire and hose is properly connected, go back and double check that all coolant and vacuum hoses are connected. Check that your oil drain plug is installed and properly tightened. If not already done, install a new oil filter onto the engine. Fill the crankcase with the proper amount and grade of engine oil. Fill the cooling system with a 50/50 mixture of coolant/water.
  1. Connect the vehicle battery.
  2. Start the engine. Keep your eye on your oil pressure indicator; if it does not indicate oil pressure within 10 seconds of starting, turn the vehicle OFF. WARNING
    Damage to the engine can result if it is allowed to run with no oil pressure. Check the engine oil level to make sure that it is full. Check for any leaks and if found, repair the leaks before continuing. If there is still no indication of oil pressure, you may need to prime the system.
  3. Confirm that there are no fluid leaks (oil or other).
  4. Allow the engine to reach normal operating temperature (the upper radiator hose will be hot to the touch).
  5. At this point any necessary checks or adjustments can be performed, such as ignition timing.
  6. Install any remaining components or body panels which were removed. prev.gif next.gif

Oct 17, 2010 | 1995 Ford Thunderbird

1 Answer

Stopped during use with half tank of gas left. Only 1 hr. use last year and 1 hr. this fall since new. Starter pulls same as when new, but fresh gas/oil mix, ether, and much cranking result in no signs of...


look inside where you took off muffler look at piston ring & piston & also cylinder wall if scarred & pitted then the engine will not start needs to be rebuilt with new ring,piston,cylinder head you might have also broke the flywheel key if its broke you will get a spart but weak & also will not start because timing is off it will act like it wants to but wont

Nov 09, 2009 | Garden

1 Answer

Poulan leaf blower bv1850 Runs greate for about 30 seconds, then dies. Replaced fuel lines and installed carb kit. No better. Adjusted the one adjustment screw out 1-1/2 turns out for starting position....


Most likely low compression caused by stuck piston rings or a scored piston and cylinder. This unit was made by Poulan and they have had an epidemic of this problem. The solution is to tear the unit down and put in new piston rings. Before you install the new rings you need to get a sheet of glass and some 600 grit wet dry sand paper. Sand each ring down about .002 to .003 and reinstall. This should solve your problem as long as you have good fire and the piston and cylinder is not scored.

Sep 20, 2009 | Garden

2 Answers

SEIZED PISTON


excessive piston clearance.really needed bore job with oversized piston,not just honed and rings.measure piston to cylinder clearance,check spcifications and verify

Apr 05, 2009 | 2003 Yamaha YZ 125

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