Hi everyone

I'm new to this forum. Been having a lot of problems with this bike and was hoping some of you folks could help me out. I have a 1993 KE 100. This bike had problems from the getgo. Had no power and would die unless you kept the revs up. First I cleaned the carb which was pretty dirty and gunked up.
It helped a little. Next I pulled the head and cylinder off. A circlip came loose and scoured the cylinder and piston. This has the electro-fusion cylinder. So I ordered a new cylinder and piston rings gaskets everything for top end rebuild. Got it back together and it started on the first kick. Let it idle for about 3 minutes and kept a load on it. No lugging it kept it in second gear at about 15mph. Well it started smoking a little which I thought might be some oil in the muffler which is where it was coming from. It finally got worse with the smoking so I shut it down. Oil coming out of the exhaust manifold. And its leaking underneath. Havent been able to find where thats coming from. This bike was abused when I got it. Anyway I think maybe the seals are leaking now but I dont really know. Anyone ever have these problems? thanks for any help.

 

Hmmmmmm well first of all welcome to the forums. You may have a gasket on wrong, or pinched a little. How tight are the rings? They may have to seat a little before the smoke clears up, although not that long. I would pull the head again and look at everything. Its only 4 bolts since its a Two smoke...I mean stroke.

 

The rings are not installed properly is my first guess.

bummer on the issues, but welcome to KF

 

Thanks for the replies. Got around to pulling the head and cylinder today. All looks good.
I used a Wiseco piston and rings. End ring gap was set to .014 or .35mm according to the spec in my book. The rings came with instructions that say they can be installed with either side up.

Gona try putting it back together and see what happens. I talked to a Kaw mechanic and he said the muffler might be clogged with oil since it was running badly before the upper rebuild. He suggested a place that specialise in a soaking tank. I hope thats all it is. Before I shut it down it was really smokin. thanks again. ljm

 

That is a good point. The muffler packing would have to be really saturated with oil to cause this with oil dripping out the stinger. What compression reading are you getting after the new top end?

 

Dragone

Compression is around 140. Has anyone had any luck putting in new seals without splitting the cases? It probably would be tricky to do but I think its worth a try. Will be a last resort thing.