I have a 2004 KFX80 that I bought for my daughter for Christmas. Previous owner said his kids out grew it and it just sat around for 6 months. I brought it home, changed spark plug, new air filter, cleaned carb and had it running in about 2 hours. It would start but would take a bit to get it running. Finally it ran great for several hours and then all of the sudden wouldn't start. Eventually I had to replace the starter and I put the entire motor back together and now it just cranks over but wont start. I have great spark. I did a compression test and it has 120 psi. I called my repair shop and they said that its possible to have a crank seal go bad. So I just took the cover off and no signs of leaking. But what I did find instead was metal pieces and filings stuck to the stator. I haven't gone any further yet but I plan on pulling off the drum and find out more. Would anyone know where the metal could come from?? Is there a possibility for the stator going bad? I heard some grinding when I try to start it. Could it be crank bearings?? And how hard would it be to change them? Or is there something else majorly wrong? With a low budget for repairs I am trying to do all the work myself. I have to get this running for my daughter! Any help would be greatly appreciated!!

 

Welcome to the forums.
Wow......
At this point, taking it apart and inspecting things is going to be what's done.
The metal shavings , I agree, are confusing.
IMO, You will be pulling both the stator and clutchs out for inspection. You will put new seals in at that time cuz they are like 5 bucks.
Maybe a stator bolt came out, maybe a clutch plate got tore up and ended up in the stator form airflow..???
Guess we'll see.
Make sure you pull straight on the flywheel.
Please keep us informed.

 

Thank you for replying. I have already pulled the side cover of the clutches and there were no sign of any metal shaving it was really clean and also there were no signs of leaking seals. But most of the noise was coming from the other side of the motor where the plastic fins are. They do look like aluminum shavings and there is a very small amount of oil? or gas? at the bottom of the plastic case. I don't think its even enough to use more then 2 Q Tips to clean it up. Is there a chance that I could have ruined the stator? Of do you think maybe I would be able to just clean them up and have it still work? What is involved changing the crank seal and bearings?

 

When you pull the flywheel we'll both know.
I'm pretty sure I have a stator here if needed.
The bearings are internal. It's a big job to replace them.
The seals are easy. They simply pry out and press in. They are on the outside of the cases. You'll see the one when you pull the stator.

 

Well I guess i have BAD news. I just pulled the stator drum and it had metal shaving stuck inside! Along with heavy shaving at the bottom of the case. I pulled the stator and the crank seal was already out just hanging on the crank shaft, and the bearing are shot!!! What now?? I really don't have the money to bring it to the shop to have it fixed. I know the parts are cheap but splitting the case is new to me!!!! Can you give me some suggestions?? Oh what can i use to clean the metal and grease off the stator and drum? Will brake klean do?

 

Well I pulled the motor out and started to dissemble it. I took carb off and found crap in it again. I then took off the reeds and there were metal filings on them. But when I looked into the cylinder the piston is half way down where I believe I see the piston or is it a sleeve of some sort. For my case I hope its a sleeve. Because the side of it was really scored!. But remember I had 120 psi compression before I tore it apart. Now I have a question?? Do I have to take apart the entire clutch assembly to change everything OR can I just pop the jug off and pull the right side of the case where the damage it an fix it from there??? Or is there screws that hold on the right side casing?? If anyone could help I would really appreciate it. Also what is a rough estimat that it would cost for me to do the work and just replace parts. And does anyone know of a really reasonable parts dealer?

 

Oh boy.............
Yes, you need to remove all the clutchs to split the cases. You need to service the clutchs anyways.
This job is not for the timid or inexpierienced.
I'll send you a PM. This case thing is long winded.