My buddy and I went out riding last weekend in the desert, and when we first got out the we rode about 30 miles, and then we stopped to take a break for a while. My bike ran flawless, and we decided to go for another run. My bike started first kick, and I pulled away from camp and it felt like a spark plug was starting to foul (never happened to me on this bike before, but I had a high performance KX125 back in the days before high tech plugs, and it would foul plugs if it wasn't warmed up properly) so I pulled it in neutral to figure out what was happening, and it wouldn't rev above 1/4 throttle. I opened my gas tank, and I could see my IMS gas cap seal (less than one years old) disintegrated and was sitting on the petcock screen. I thought I had found the problem, but this wasn't it. It would run better with the choke on, so I new there was a fuel supply problem. Got around to cleaning the fuel tank out yesterday, and from the flow coming out of the petcock before I cleaned it, I new a clogged petcock screen wasn't my problem. Took off the throttle from the carb and found this in the first picture.
For those of you who don't know, I bought this Ex Team Green bike a few years ago and haven't done anything but basic maintenance and ride the hell out of it since I bought it. I did a leakdown test on it when I first got it, and it seemed very tight. Watching all of these builds and various project on kxriders, and being an engineer/ex mechanic, it was hard not to pull the bike apart to check everything out and freshen it up. I just couldn't bring myself to disabling the bike for a while because it runs so good, and it has never missed a beat. After I found the broken needle jet, I went ahead and pulled the reeds out for the first time. They look brand new, but I will replace them for piece of mind. The piston looks pretty good, although there appears to be some cracked intake bridges. I will send it to Kaw Rider when I do the rebuild in the next six months or so. Take a look.
I also thought some of you would like to see how Team Green modded their radiators for the desert. Completed welded up, thread boss welded in with spacers to get the radiator shrouds positioned to grab the max airflow over the radiators.