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Customer brought in this bike for no response when put in gear. After getting into the transmission I found the main shaft for the clutch had been stripped where the gears mesh up and also the shaft for the gears had been broken in half. I replaced all broken parts and reassembled the transmission. Now it makes a knocking noise in low gear and in reverse. When in neutral it tries to roll reverse while making the same knocking noise. I’ve disassembled and reassembled it several times with the same result. Any ideas??
I have a 1994 Kawi Bayou 400 which had been running well until it sat for about a month. I left the carb dry while it was park and the temp had dropped below 0C in this time. Pulled it out last night to go for a ride and it fired up just like it should but noticed when I started to head down the road I could hold it to the bar and it didn't seem to accelerate. Lower gears weren't as noticeable but 4th and 5th it just seemed to have no acceleration and half or full throttle made no difference. if I tried to go into 5th gear with any throttle it would stall. I turned around and just poked home very slow and it seemed to stay running but this was between 15 and 20 km/h max.
I have taken the carb apart and it appears to be clean and nothing stood out on inspection to have dirt or ice. Is there something I should dig more into?
I have checked the plug and it appears to be sooty with easily rubbed off carbon. I plan to get a new plug today and test.
compression with the throttle wide open is 175 psi.
I have opened the drain plug in the exhaust thinking there could be a mouse in the exhaust or something but no difference.
I do find the engine is tickity compared to my 2000 Honda but I am not sure if this is just me looking for issues or if it has always been this way.
If anyone has any insight I would appreciate it.
In the last 6 months I have done new oil and filter ( mystik synthetic)
new Peak RPM CDI
I have noticed the fan comes on more often with the new CDI, could this be a program thing?
So this’ll be long I’ll give all the background first to see my issue skip to the ***
Hey I picked up a pit bike and a foreman for 800 the pit bike was running but the foreman was locked up. Sold the pit bike but when I took the top end off the piston I only found half a piston left. So knowing the rest of the piston was down in the crankcase I knew it had to be pulled and gone thru completely.
to pull the motor I went ahead and pulled the rear end off and unbolted the front diff to pull the drive shafts and pull the motor. Now I have the motor torn down completely and have all the parts of the piston removed. I know the rod and crankshaft is shot (heat discoloration and too much up and down play rod to crankshaft).
***so I’m wondering while I have the motor apart what should I check for? I know this motor died from heat as the oil in the head smelled like popcorn. So what should I check to make sure I fix the issue (overheating I assume) and not just the symptoms (blown up motor lol).
so put simply I don’t want to just rebuild the motor to have it overheat and repeat the process after 5mins of running
Here’s some pics
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