Kawasaki KDX200A engine repairs - Episode 1 

AM's film and edit skills improve each episode.. That compression test for seals is brilliant.. I swear watching this man working lowers my blood pressure..

No corroded bolts, no stripped threads, no rounded heads, it’s a joy to work on something that hasn’t been butchered by someone who’s rough and ready or knows no better (I’m looking at you...yes you! The one who sold me my super blackbird). It’s a joy to watch someone work on bike like this too, well done and thanks for another great video

I really appreciate how Allen takes care to set up the camera at every stage, to ensure everything is clear.

Your methodical disassembly of each engine you work on helps all of us to learn how to do so ourselves. Thank you so much! Looking forward to this and each episode of this series, Allen, and cheers to you & yours!

Allen Millyard takes the Iain Tyrrell approach to "listening" to an engine to another level! Fantastic 🙂

Simplicity of an air-cooled two stroke single is a lovely thing. Your videos really are becoming short films. Love all the attention to secondary shots of walking about and garden/nature etc. Just lovely.

"Allen, there's a quicker, easier more efficient way of doing that job.", said absolutely no one, ever!! A joy to watch a master at work. Thank you for another brilliant tutorial.

A joy to watch Alan, wish I had just a small percentage of the skills you have 👍

My wife also makes me a nice cup of tea and a bowl of Moss. 😅

I lusted after a KDX200 as a teenager. Lovely thing!

As always, your calm and thoughtful narration, clear angles and the love and respect you have for your darling Tracey (and the animals) is such a pleasure to watch. You keep me motivated to work on my own projects in the garage and to maintain a positive attitude and perspective towards the challenges that come. Thank you!

I love these, I learn something new but totally obvious every time I watch. Put a hose in the crankcase to LISTEN for leaks??? Simple but genius.

Allen does an outstanding job of going over all the details of the bikes we rode as kids while making it a very enjoyable experience.

Always straightforward information on strip down Allen,really great video.👍👍

I own a 1985 KDX that I bought new in late 1984. I don't ride it so much as I am getting on in years. I am able to ride in the front range of the Rocky Mountains which are just west of my home in Calgary. This Kawasaki has been an awesome bike. I will be rebuilding the rear shock for the first time this winter. It never fails to start. I have enjoyed this video.

What a machine and also quite a fine KDX; 19 minutes have never passed so quickly.

watching these video is so therapeutic

Lovely job. Also, consider getting a Toulouse goose. They're regal and considerate and they do like to watch the sunset while standing one legged in our little tub of water. Thanks for the inspiration and keep on trucking

This made my day Allen , such a treat. Little KDX looks fun to ride ☺️

Bloody love these videos. Home after a long shift. Cup of tea, Mr Kipling fruit pie and a Millyard video. Perfection.

Another superb video Allen,thankyou,and with Charley Weaver overseeing proceedings.....just perfect Kimbo

I've a KDX 200 out here in France, and only got a .pdf English workshop manual, so this serves as both entertainment and information. Thanks, Allen.

Great stuff Alan! I've just recently rebuilt an IT175, I'm keen to see your method for balancing the crank webs.. looking forward to the next episode! 👍

That idea of blowing pressure and listening through the tube is brilliant,thanks Allen your always teaching me something new

Another grade A video Allen,I never miss one,and have watched most several times.always a treat,thanks.

An absolute pleasure to watch, as always.

Beautiful bike, I’ve always loved those old kawasaki enduros. I had a Honda that had that nikasil lining on the cylinder, I bought it new and it didn’t take long and it blew up and I was told I had to buy a whole new cylinder as it had that coating and couldn’t be machined. I refused to believe them and brought the cylinder to a local machinist and had him bore it out and press in a steel sleeve. Worked perfectly after that 👍

Two cups of tea but no cup cakes! What is the world coming to? Excellent video by the way-thumbs up for the algorithm.

I had a 1986 KDX200 and sold it to the bike wreckers due to this issue (was fouling the plug and wouldn't restart one ridden ). I had no idea about bike engines back then (25 yrs ago ) i bought another KDX200 though, a 2001 model which I regret selling as I haven't owned another bike since. I'm really enjoying your rebuild videos.

Tracy is the best! So excited to see the rest of the series.

No annoying music, no desperate pleading to like and subscribe, just a genius at work happily barbecuing motorcycle parts. Oh, and a hedgehog update. Marvellous.

I races one of these in the Idaho city 100 enduro in 2016 . These are great machines, I paid 200$ for mine and I was on the oldest bike in the event!

Alan, your videos are both a tremendous inspiration and great therapy!

You sir, you have so many nice bikes. Thank you for anotther well edited video. Also thanks to your sweet wife!

What a great way to start my Monday. Thanks Allen.

The simplicity of the two-stroke engine is one of its many appealing traits; a pity we can't have a two-stroke road bike any more :(

Always enjoy your content Allen

Brilliant videos. I really enjoyed the Pan series, but I love 2 strokes. I'd love to be able to work on bikes with your level of skill!.

Ah a nice simple engine like a 2 stroke and light years away from that Honda ;-) Thanks Allen, another great video for Sunday evening !

Thanks Allen! Be good Stay safe, Wishing you a Deluxe week!

I always learn something new watching Allen Millyard. Today it was using grinding paste on the crankshaft to mate the rotor better. Thank you Allen.

I always used to run my 1980 YZ125 at 30:1 Engine outlasted the gearbox. I run all my 2 smokes at 30:1 with Motul synthetic 2T . Love the smell

Brilliant tip on the crankcase leakege another fine video Allan...cheers

As an owner of a 1993 KDX250, I salute its older air-cooled brother.

Brilliant bikes these are I had a kdx 250 I used to use it bk and forth work and on a Sunday go up the mountain and Rip around the old coal tips big banks it would pull me up anything I was brave enough to go up it's a pleasure to watch u work on bikes👍

You`ve done it again Allen, you`ve made it all look so easy 😀

Charming genius at work, Tracey's lovely smile & a casual walk-on by the 'Hedgehog from Atlantis'. Where else but here?

It’s great to see you haven’t whacked your thumb recently ! Great videos Allan.

Literally the bike I did my licence test on about a thousand years ago as a broke teenage apprentice! Kept it for about five years and used it for everything. Tough as nails. Cant wait to see this running.

Nice going Mr Millyard ! A late motorcycle mechanic friend of mine, was really good with 2-stroke machines. In discussion with him once about single-cylinder crankshaft wear, he explained that the area of the crankshaft diametrically opposed to the connecting rod's crankshaft pin, sees wear the most in the ball bearing inner race fitment area. Reason being, this part of the crankshaft bears the most load on the firing stroke. Too, the side with the heavy magneto/generator flywheel suffers more wear than the side with the primary gear. I would guess that crankshaft metallurgical issues could be taken into consideration also. Thanks . Trinidad & Tobago. West Indies.

One word, Legend , im not a motorbike fan, but i really enjoy your videos Allan,, i now use Abranett cloth thanks to you sir, wondeful stuff, and with the extraction there is zero dust , keep them coming sir

Great video Allen I always enjoy watching your easy going approach to the jobs you do Nick Australia

You do such great work and show how to do the work

Great job getting down to the root cause of your transmission oil infiltration. I was surprised to see the wear on the crank and main bearing whilst the rest of the engine is near mint. Your video production and mechanic skills are amazing.

I watch your mechanic skills in amazement. I spent all day yesterday trying to remove the rear tire from my NT700V. I do wish you were here to perform your magic.

Loved that , cannot wait for the rebuild - keep up the great videos

What a nice, relaxing and informative video! I miss the two-strokes. It's all bloody overhead valves and timing chains these days haha.

Great to see enduro bikes here!!

"Thanks for watching." The pleasure was all ours, as always.

Look forward to the next video Allen thanks for sharing

Hey Man, That Was Really Good! You Lucky Duck, I'd Give Anything To Have A KDX-200! Didn't Know You Rode Enduro. I'm On The Bell & Can't Wait For Part Two!

I love coming away from your videos with a new little technique Allen! Pressurised crankcases and listening for air escaping! So simple but I’d never have thought of it! Love your videos and your work! Thank you!

Another Awesome video with a Charlie Weaver appearance well done Sir😀👍🥰

I worked at a Kawasaki shop from 73 to 83. When the KDX 175 came out in 1980 I thought it was amazing. Light weight, torquey, good handling and adequate suspension. The owner of the shop rode enduros and the 175 was what he used so I got to ride them a good bit. WARNING!! Never hit the actual magneto flywheel with a hammer! Not even a plastic mallet. The powdered magnets will shatter.

Interesting as always Allen!!...........thanks........looking forward to your next one!!

Another very, very nice video!Thanks a lot! Greetings from northern Germany Manfred

Excellent as always, thanks Allen.

Loving all the content Allen! It seems you've got plenty of bikes stashed away to play with!

Great video and a nice cup of tea in the lunch break. No cupcakes this time. Great skills on this engine, everything you repair looks easy and simple. Thanks for sharing.

Would anyone else here watch a video by Allen on how to find a Tracey? You’ve definitely got a one in a million mate. Cup of tea AND a smile. Perfect. PS That taper tip has given me hope that I can cure the dodgy Morse taper issue on my Clarke pilar drill. It keeps ejecting the chuck - even when it’s only mildly stressed. But I might need to remove the tang to do the job properly. That was the last thing I bought from Machine Mart. The alternative option is to make a vertical miller style drawbar. Anyway, great vid as always. Wonderfully simple engine to work on. Thank you for sharing.

What a treat to watch!

A nice simple project by your standards Allen, looking foward to seeing it get a new lease of life. The Hedge hogs will soon be "at it". Spring is just around the corner,Just make sure you draw the curtains at night to give them some privacy:)

The genius Allen 👍👍

Looking forward to the next instalment, I sold my bikes around 5 years ago, honda 400/4 and CB 750K along my tools and lift, after watching your videos I’m drawn to eBay.😊❤ keep them coming, and thank you for all your posts.

Thanks Allen, made my Sunday night. Fascinating incite into top grade engineering. Take care, regards, John.

I raced air-cooled KDXs for 6 years through all the British, Scottish and North of England Championship enduros, including the 1988 ISDE at Mende in France, battling my way to about 104th (!!!) place in the 250 class, A great bike to ride, never missed a beat or broke down in all those events, and still competitive even now in the right hands some 30+ years later. Arguably one of the best off-road bikes ever made.

also the grinding paste on the tapered crank is a great idea, I bought a 1977 Honda CG125 recently and on my first ride out the flywheel spun on the crank thankfully no damage apart from a worm down woodruff key (Honda GX160 woodruff was the same phew) then properly torqued down with some thread lock but if I ever have it off will definitely be doing the grinding paste!

Hi Allen, something a bit different this engine. Plenty of wear and worn seals to deal with, loved the quick test of pressurising the crankcase and having a listen, also stripping the crank down was interesting. Soooo glad to see the tea was appearing frequently (well done Tracy) and the BBQ paintbooth was back in action. Only bit missing was the "grass workbench".. Alex.

Excellent video ,Alan makes it look so easy

Really enjoyed that, Thanks Allen.

Always a joy to watch, you do great work, we appreciate the time and effort you put in to making these videos. You can tell when someone knows what they are doing, by the way it looks so easy.

I never seen one that nice even when they were new.

Another great to watch video Allen. O, and Tracy does look after you.😍 Thanks you for showing us all.👍 John.

This motor almost seems simple compared to the Honda rebuild - not far off a Villiers 9E (remember those?). Always enjoy these posts, gives me a constant nudge to get on and do something with those projects in the garage.

Always fancied a KDX 200, can't wait to see it go back together.

A day to remove the ST1100 engine, a hour (or so) to remove this one! Nice video.

thank you allen. in these modern times of noise and rush, what a peaceful pleasant and relaxing watch 🙂🙂

Nice video Allen, was surprised to see the wear on the crank! Like you I was saying to myself that looks OK, fair play for splitting it to make sure.

Such a pleasure to watch…makes me think of the good old days with my little Zundapp/ Puch and Yamahas. Thanks Allen!

Another magic video Allen, I love watching you work and learn so much in the process! I find myself watching the timer bar at the bottom as I don't want it to end!!!!❤️👍 Tracey is just such a megababe too !

I love watching the engine coming apart and fine it hilarious that it'll go back together again, and be better that before.

A nother master class on engine repairs, you can tell that it's previously had the Millyard magic touch on it because everything comes apart so easily. Removing that flywheel, back in prehistory Villiers engines had a built-in puller on the bolt. It was a really great idea, looking forward to part two.

Brings backs memories of my 92 kx250 engine. Nice work, I am awaiting part 2 Cheers Allen.

Excellent work as always. So relaxing to watch and listen to your calm, measured approach to everything mechanical. Thanks Allen.

Another fine day with Allen & Tracie

Greetings from Maine .I am assuming that my smoky 2001 KDX has many ,all or,even more of the same worn out parts .I do love riding my kdx in the woods of New England .You make rebuilding look so easy !

Hello from me in Australia. Your methods are the best. I found an abandoned air compressor the other day and this video has given me help. So from me and Burt Munro keep up the good work. I'm off to have a nice cuppa tea.

Another great video, I really enjoyed this one as I prefer small bikes and especially small off-road bikes. Thanks Allen. We used to use the rubber tube listening device to tune multiple carburettors on cars. Les

I think you are an absolute genius, ive now watched all your videos and you are seriously amazing, you have the "just get it done" attitude, think of an idea, get the hacksaw out and start cutting engines in bits, Im about to start a youtube channel trying to make a vintage style cafe racer from an old RG125 i have no idea what im doing with youtube, but ill give it a go, just me and my shed :)

Love seeing this content. I would never have known about the lapping trick with the flywheel shaft taper. It's also cool too see the all of the EngineZilla content, but I won't be doing any of that soon (or ever). I leave high skill levels to the highly skilled. 😅