- Jul 13, 2001
Just bought a 96 KDX200 from the second owner who had it for 5 years. At idle and up to about 3000 RPM it has a noticable mild knock/rattle. He blamed it on the KIPS system. I pulled the head and cylinder, measured the rod radial play (up and down) with a dial instrument. Measured about .001. Seemed ok. The piston had about .0035 clearance at the bottom of the skirt but about .020 at the top. Replace the piston, wrist pin, bearing with a Wiseco which had about .014 at the top and .003 at the bottom. The mild knock is stil there. When I pull in the clutch lever the "tone" of the knock sounds a little different. Changed the gear case fluid, no help. Any ideas?