the drawing it together with the engine bolts is brilliant. thought i was going to need a press but that worked absolutely perfectly. new crank seal on the flywheel side was a bit stiff at first but it spins nice after rotating a few times
@@2strokeguru im already over my head with this project, never touched one of these before but I just dove right in. your vids have helped a ton, there isnt another resource that even touches the detail you go into, not even the shop manual. the bike was pretty well trashed and im sure you wouldve considered it a parts bike but i was looking for a project.
@@2strokeguru got the case halves back together the other day and it shifts through the gears while turning the output shaft, but sometimes it doesnt fully engage 5th gear. do you think that will still be a problem at rpm? gear teeth, dogs, drum, and shift forks were all in (surprisingly) good condition
@@bcouri1 many of my bikes started as parts bike I look at bike different than most I see a diamond in the rough I am happy my videos helped send me a friend request on Facebook I would like to see the project
@@2strokeguru i'll just make a video outlining everything and upload it here in a day or two. waiting on a box of parts (the worst part) i don't have a facebook anyway.
gracias amigo por la ayuda tengo una kh100 1979 y tengo difficultad para armar el motor, tus videos son gran ayuda para mi. te envio un gran saludo desde Montevideo Republica Oriental del Uruguay. NO SPEAK ENGLISH
@@2strokeguru Hi Kevin, happy independence day from a wet and windy Wales in the UK, got my motor tore down last night but needs bearings in the crank so will have to order some. Have you ever built an expansion pipe for a KE100? found some low pipe build plans but nothing on the internet for a high pipe like the KE has, really hard to find good pipes in the UK so not sure what to do, any ideas? Many thanks.
Great video - super helpful. The ball bearing you placed on the end of the input shaft with Vaseline, do you know what size it is? I have a 1983 Kawasaki KC100 companion.
I have a kb 100 it's very similar to the ke 100 ,kh 100 an gto100 but all these bikes are using 5speed gearbox and mine is having 4 speed can I make it a 5 speed ? If yes then how?
Hey Kevin, i have a 1990 ke100b9 and in my Haines manual and on exploded diagrams on part house websites it shows there is a thrust washer that goes on the end of that shaft. Im hesitant to put my engine back together until i clear up the confusion. Are you sure there's no washer that sits there?
Alright, is it an actual washer that sits on the shaft or is it a disc that sit inside the brass bushing? My research has given me conflicting results. Thanks again for your help.
In this video, around the 2 minute mark, you mention the thrust washer is "built into the brass bushing". Are you referring to the lip on that brass bushing that protrudes from the inner side of the case? Because that ware pattern on the 5th gear on the input shaft matches the size and shape of that lip on the bushing. Your experience would be greatly appreciated!
sir? I have a problem with my bike now, oil was leaking from the left cover, on the adjustable screw like the UK cover.. first I thought that the leak was on my shifter seal or sprocket, but its coming out from that screw... I opened it and a ball bearing falls. My question is, Is there any oil seal inside that hole? can I replace it with a new one? and do I need to split the case to change it? please help.
@@2strokeguruno sir, the hole between the magneto and the sprocket... you show it in this video, the two types of left crankcase, I got the one with the screw..
@@2strokeguru no sir, I check it just right now and theres an oil seal and was damaged, now my problem is do I need to open my engine just to change it ?
Hi I have a 96 Kawasaki enduro ke100 that I got running and seemed to run just fine at beginning and went maybe a mile and on way back to park in lost compression what would be the cause most likely be very thankful for your help you seem to know alot about the ke100 please help me if you could thank you
Eric Lillard loss of compression is the result of engine damage I have a few questions do you have a stroke oil in the tank 2nd is the tank vent clogged 3rd are you running the bike with the carb side cover off could be a lean condition
Kevin Bergeron I have cover plate on and the gas flows out fine of gas tank line and use the oil pump to mix oil to gas I did hear like it seemed like a little tink like if you dropped a coin on still then nothing and died and tried to start it up and no comparison to kick starter
Kevin...... you know that ball in the end of that shaft.... well i just lost it in the dark shed! !!! shit!! what size is it? do you know?, i have all the old bearings from the rebuild so maybe i can cut one open and use a ball, also. i bought half a spare motor on e- bay and it didn't have a ball but that shaft end, and the screw we have on UK bikes, was all melted up! the needled were welded to the shaft and i'm thinking from not having a ball!
Hi my name is Eric was wondering if you would have a jug and piston to fit a 96 Kawasaki enduro ke 100 2 stroke or have a ideal of were I might find one for a reason price to buy names Eric
Kevin Bergeron the piston ring broke and scratch it pretty deep that's why no compression I can't seem to find a jug and the ones I do are so damage there not worth even trying to fix so if you had a jug you would sell and a high compression head seen were you talked about the high compression head it not got or want to sell high compression head that is ok my head is still really good but the hug is really bad scratched what is the biggest bore you can safely do on a jug for a key 100 and still have no issues at all because I took it in to have it hommed out and the guy said he don't know if it can even be hommed out because the biggest piston he found for it was a 47 mm and he said it needs at least 50-57 I think so if don't have jug for sale what's the biggest hommed out I can go on the jug and have no issues your information is very much appreciated and help
Been watching videos 2-4 quite few times and your idea of using the motor mount bolts was perfect! The G4TR crankcase is together. Thanks Kevin
thats awesome happy to help
the drawing it together with the engine bolts is brilliant. thought i was going to need a press but that worked absolutely perfectly. new crank seal on the flywheel side was a bit stiff at first but it spins nice after rotating a few times
I enjoy sharing tech tips and tricks help a lot of people
@@2strokeguru im already over my head with this project, never touched one of these before but I just dove right in. your vids have helped a ton, there isnt another resource that even touches the detail you go into, not even the shop manual. the bike was pretty well trashed and im sure you wouldve considered it a parts bike but i was looking for a project.
@@2strokeguru got the case halves back together the other day and it shifts through the gears while turning the output shaft, but sometimes it doesnt fully engage 5th gear. do you think that will still be a problem at rpm? gear teeth, dogs, drum, and shift forks were all in (surprisingly) good condition
@@bcouri1 many of my bikes started as parts bike I look at bike different than most I see a diamond in the rough I am happy my videos helped send me a friend request on Facebook I would like to see the project
@@2strokeguru i'll just make a video outlining everything and upload it here in a day or two. waiting on a box of parts (the worst part) i don't have a facebook anyway.
Really amazed and happy to learn from you ❤️
Can you please share part 1,2,3 of this video.
Thank you there 123 are up
gracias amigo por la ayuda tengo una kh100 1979 y tengo difficultad para armar el motor, tus videos son gran ayuda para mi. te envio un gran saludo desde Montevideo Republica Oriental del Uruguay. NO SPEAK ENGLISH
Superb Kevin! Thank you!
Welcome
Thanks for thinking of us in the UK, didn't know the US and UK engines were not quite thew same.
There are a few differences most is the same
@@2strokeguru Hi Kevin, happy independence day from a wet and windy Wales in the UK, got my motor tore down last night but needs bearings in the crank so will have to order some. Have you ever built an expansion pipe for a KE100? found some low pipe build plans but nothing on the internet for a high pipe like the KE has, really hard to find good pipes in the UK so not sure what to do, any ideas? Many thanks.
@@richardamner7432 they are hard to find I have built a couple
Thank you sir..Great video.. i have on Kawasaki bajaj 100 (kb 100) in INDIA
That's awesome thank you for your support
Is the Ke100 and kh100 has the same connecting rods? Cuz i cant find ke100, i only find kh100. Pls help
where did you buy transmission gear thanks
I don't I buy parts bikes but check ebay is your best bet
@@2strokeguru my transmission gear is broken my circlip is being broke and my three gears broke
@@2strokeguru thanks
Great video - super helpful. The ball bearing you placed on the end of the input shaft with Vaseline, do you know what size it is? I have a 1983 Kawasaki KC100 companion.
sir kevin i have a motor like that here in the Philippines...
but it's hard to find any part like you have...
I have a kb 100 it's very similar to the ke 100 ,kh 100 an gto100 but all these bikes are using 5speed gearbox and mine is having 4 speed can I make it a 5 speed ? If yes then how?
Great question I will look into that what year KB100
@@2strokeguru thanks for replying it's a 1989 kb 100 I will give u every information u need
@@sumedhovhal8156 awesome thank you
@@sumedhovhal8156 ok you can make it a 5 speed
@@2strokeguru ok. how and what are the things I need to change , will it fit in the engine case which is made for 4speed
Hey Kevin, i have a 1990 ke100b9 and in my Haines manual and on exploded diagrams on part house websites it shows there is a thrust washer that goes on the end of that shaft. Im hesitant to put my engine back together until i clear up the confusion. Are you sure there's no washer that sits there?
It's a (US) motor btw, not the (UK) model.
Yes there's a thrust washer
Alright, is it an actual washer that sits on the shaft or is it a disc that sit inside the brass bushing? My research has given me conflicting results. Thanks again for your help.
In this video, around the 2 minute mark, you mention the thrust washer is "built into the brass bushing". Are you referring to the lip on that brass bushing that protrudes from the inner side of the case? Because that ware pattern on the 5th gear on the input shaft matches the size and shape of that lip on the bushing. Your experience would be greatly appreciated!
@@coldkill47 yes
Hello sir. I have this motorsickle and problem power kick lose quickly
The kickstarter is keeps losing
Yes sir. What do this?
how to timing the rotary valve i cannot see
This bike 5speed or 4 speed?
5 speed
sir? I have a problem with my bike now, oil was leaking from the left cover, on the adjustable screw like the UK cover.. first I thought that the leak was on my shifter seal or sprocket, but its coming out from that screw... I opened it and a ball bearing falls. My question is, Is there any oil seal inside that hole? can I replace it with a new one? and do I need to split the case to change it? please help.
Are you talking about the clutch adjuster screw
@@2strokeguruno sir, the hole between the magneto and the sprocket... you show it in this video, the two types of left crankcase, I got the one with the screw..
@@2strokeguru you showed it at 7:00 minutes in the video
@@jervinclainandalahaw632 check your oil level seems over full
@@2strokeguru no sir, I check it just right now and theres an oil seal and was damaged, now my problem is do I need to open my engine just to change it ?
When you put it back together does it get hard to turn at the very end just before it closes and is everything suppose to turn freely?
In neutral it should spin freely it doesn't spin freely after reassembling gently tap with a rubber mallet the end of the shaft
Kevin Bergeron the piston seems to have a bit of hard turning, the clutch shaft doesn’t want to turn
@@Inotterus remove the head and inspect the cylinder
Hi I have a 96 Kawasaki enduro ke100 that I got running and seemed to run just fine at beginning and went maybe a mile and on way back to park in lost compression what would be the cause most likely be very thankful for your help you seem to know alot about the ke100 please help me if you could thank you
Eric Lillard loss of compression is the result of engine damage I have a few questions do you have a stroke oil in the tank 2nd is the tank vent clogged 3rd are you running the bike with the carb side cover off could be a lean condition
Eric Lillard send me a Facebook message
Kevin Bergeron I have cover plate on and the gas flows out fine of gas tank line and use the oil pump to mix oil to gas I did hear like it seemed like a little tink like if you dropped a coin on still then nothing and died and tried to start it up and no comparison to kick starter
Kevin Bergeron how do I find you on Facebook can't seem to find you on there
Eric Lillard you are going to have to remove the head and cylinder for inspection of damage
Kevin...... you know that ball in the end of that shaft.... well i just lost it in the dark shed! !!! shit!! what size is it? do you know?, i have all the old bearings from the rebuild so maybe i can cut one open and use a ball, also. i bought half a spare motor on e- bay and it didn't have a ball but that shaft end, and the screw we have on UK bikes, was all melted up! the needled were welded to the shaft and i'm thinking from not having a ball!
Hi my name is Eric was wondering if you would have a jug and piston to fit a 96 Kawasaki enduro ke 100 2 stroke or have a ideal of were I might find one for a reason price to buy names Eric
Eric Lillard what is wrong with yours
Eric Lillard if its scored you can send it out to have it recoated
Kevin Bergeron the piston ring broke and scratch it pretty deep that's why no compression I can't seem to find a jug and the ones I do are so damage there not worth even trying to fix so if you had a jug you would sell and a high compression head seen were you talked about the high compression head it not got or want to sell high compression head that is ok my head is still really good but the hug is really bad scratched what is the biggest bore you can safely do on a jug for a key 100 and still have no issues at all because I took it in to have it hommed out and the guy said he don't know if it can even be hommed out because the biggest piston he found for it was a 47 mm and he said it needs at least 50-57 I think so if don't have jug for sale what's the biggest hommed out I can go on the jug and have no issues your information is very much appreciated and help
Eric Lillard what year ke100 the aluminium cylinder you can't hone you can bore it and re nikisile coat it
Problem in my bike is not going move r kb 125
It's a 96 Kawasaki ke100 enduro 100 cc engine would you have a jug you would sale
Eric Lillard every thing I have left needs to be repaired
Okay thank you if you happened to know someone or a place to find a jug please let me know thank you for your time
Eric Lillard I will let you know