Motorcycle Repair: kdx 200 1986 not starting, lean mixture, bill silver

Question
hello bill,

I have been given a kdx 200 1986, the piston broke in side the barrel. so i have bought a new piston and rings, and had the barrel rebored! replaced everything, put the motor back in the frame and tried to kickstart it....but nothing!
i have checked spark..i have that,i have put fuel down the head put the spark plug back and tried to kick but still nothing!i have noticed that when i kick i get fuel cuming out of the back of the carb...could my piston be in the wrong way? i really don't know where or what to cheek from here! please can you give some help to solve this problem!

many thanks,

shaune eveleigh
south Africa

Answer
Shaune, Lot of variables here...  Did you get all the pieces of the old piston out of the crankcase? If there is any metal left it can fly around inside the ports causing more damage or fouling the spark plug with debris.

Pistons are generally marked with an arrow that must be facing the front of the engine. If you have good compression, then you might have to clean out the carburetor idle jet and all the other passages, both air and fuel.

Some spitback at the carburetor intake is normal for a 2 stroke.

Check the compression, verify that the spark is good and timing is correct. It could be an erratic CDI module if equipped.

http://www.cmsnl.com/kawasaki-1986-c1-kdx200_model11773/partslist/

A broken piston is a serious condition and it the cause should be determined. If the ignition timing is erratic or incorrect or the piston seized from lean mixture or other causes, the situation must be corrected before you go riding again.

Bill Silver