1982 KDX80 Issues

[Revis]

Alright, I still got a few problems that I've dealt with for a while. I'll lay a few on you so if you have an answer you can throw it up there.

Kick Start:
I have to push start this bike every time I ride it. It's a real pain. I kick it, kick it, and kick it. And the thing will turn over just not enough to start up. Tried choke, no choke. If you have an answer to that it would be great.

Unexplained high revs/bogging:
This one is a brand new one that makes me want to light something on fire. After riding for about 3 minutes. Doesn't matter which gear, or how fast, eventually the thing will just rev like it's being held full throttle. I'll pull in the clutch to avoid not crashing, and it just revs higher. So I keep riding it to see if I can't get it home. Whenever I give it a little gas then it bogs like hell. And once it starts bogging, it just keeps on until I slow to a stop in the middle of a field 2 miles from my house. I have cleaned the carb out. The carb is about brand new. Last summer I got a new coil, cleaned exhaust, Just got a new plug. I can't find the reason why it's doing this. And it's driving me insane.

Clutch:
This is a pretty fun one. I can adjust my clutch to where I actually pull it in and the wheel will be able to move freely, then when I get it running the damn thing won't budge. It's like the clutch is all the way on without me pulling it. Or, theres option b. Loosen it up to the point where it will move and everything just fine. And basically no clutch. When I pull it in it gets a little better, but it's like it needs a hell of a lot more play than it has or something. I'm guessing maybe it's worn out inside and needs some new parts for the clutch mechanism because this is just ridiculous.

Any help would be greatly appreciated.

[KDXGarage]

The piston and rings are probably worn out. The cylinder, head, etc. needs to be taken off and inspected and measured. If you don't have the tools, then take it somewhere and pay them to do it.

The clutch needs to be taken apart. It's 28 years old, so parts do wear out over time.

[Revis]

Fixed kickstarter, I took the head off which, somehow was only tightened like finger strength. And that could be an oxygen leak causing it to rev real high. But I had a bunch of scarring on my piston and head like something bounced around and beat the hell out of it. I might get a new piston and rings but it was bored and brand new piston this year so I think the only issue was the head not being tightened. But I probably will get a new piston.

[KDXGarage]

So the cylinder was sleeved at some point? You might want to take the cylinder off and check the cylinder and piston.

Maybe a spark plug electrode broke off inside the cylinder.

[Revis]

I did, everything was all good with the cylinder. It's just on the top of the piston and the bottom of the head where it looked like somebody just put a razor blade in the spark plug and it beat the **** out of my head and piston.

[Revis]

And that electrode could be a definite possibility. For some reason I run through plugs like ****ing monthly.

[KDXGarage]

One a month is not too bad, as far as getting a 28 year old bike into shape.

[Revis]

So what would wear out on the clutch? like the plates or what would I need to inspect inside the clutch basket to see if it's worn or not working correctly?

[KDXGarage]

The plates can get too thin, or warped, or break. The basket can have notches worn into it. The springs could be too weak.

First, buy a gasket, as it will probably rip when you take the cover off.

On the high revs, check for air leaks, especially the carb to engine boot.

[Revis]

the clutch basket has outrageously aggressive notches into it. Would these be bad and how much for a new basket? I know babbittsonline.com has everything I need. But judging from $3 per screw for my covers reaching up to like $25. They are expensive. Don't ever settle for screws, nuts, or bolts unless they are extremely special. I will bet you that you can go to a good hardware store and have some fancy worker find a pound of the same thing you have for close to $5. I brought one of the cover screws in, told him I measured at home its a 6mm 100screw. He brought me bolts but I used a dremel to make them flatheads 1 lb. of these for like $4.75

As for the air leak, I figured that out. I'm not sure how this happened but I had the head bolts torqued to 30 foot pounds, and when I took it in to inspect the high revs I found that for some reason they were practically finger tightened on. And you could tell from black oil that it was leaking from the cylinder to the head. But also, I wonder if these huge gouges were causing it. There was outrageous gouges on the piston and head that I was tought would cause hot spots. Get cherry red and cause it to ignite like glow plugs. It could have been either or. Doesn't matter. Thats out of the picture.

Now basically I'm working with the clutch. I don't know how far down I should tighten the bolts that have the springs on them. I'm pretty sure they should be about to the beginning of the basket but I don't know if I should adjust them.

[KDXGarage]

You may be able to flat file the notches out, but it will not last forever and a new basket will be needed then, for sure.

[Revis]

Now I've already taken this thing apart like 3 times and put it back together. However I'm not a professional and can't tell when parts aren't like they're supposed to be.

Ignore that picture that was there. Fixed clutch. Now, if I had remembered to impact my flywheel tightly after timing it. I wouldnt be running to a chainsaw repair shop after school today to get one. But after that I should be good to go. Kickstarter is somewhat fixed. I think it needs a new spring. everythings set correctly it just doesnt have the nuts to pull it back up for some reason. random idles were either from the loose head bolts that occured somehow. or from the marks on the piston heating up and working like glow plugs. both fixed. So now I think were good to ride for a nother two weeks until i start another oh sh** thread xP.

Thank you all for your help.