KDX200 restoration
#1
02-08-2017, 07:28 AM
KDX200 restoration
Hi Guys and Gals,
LTNS since I sold my KLX I haven't been in here much and yes I know this isn't the KDX section but no-one goes there. Anyway on to my KDX200.
I have a 1999 KDX200 which has not been run for about 5 or 6 years. It's time for me to get it running again.
Got the bike up on the stand and looked it over the frame is missing lots of paint and I'd say the suspension and all the moving parts need some loving so I decided to do a complete teardown and strip back the frame and paint it. This will be a first for me but the KDX is pretty simple so I'm giving it a go. I'll also get the suspension redone for my weight with fresh oil and nitrogen (rear)
Anyway here is the before photo
And where I'm up to before it got too hot in the garage.
Next day
Didn't get time to do anything this morning, family duties, did a little bit this afternoon I think these rubbers need replacing.
Got to this stage, I have to take some off the front then some off the back etc otherwise it wants to fall off the stand. I took the boat anchor (muffler) off and the bike fell forward, fortunately slowly and I was able to catch it. I think I'll have to clamp it to the stand.
The garage got too hot and that drove me back into the air conditioning
Next day
Getting there slowly the air box and shock were a bit of a bitch but finally got them out. The swingarm bolt won't come out left it soaking overnight with WD-40 hopefully it comes out tomorrow. It not seized I can rotate it
Got onto a local bloke who will strip down the frame and swingarm for $100 I think I'll get him to do it instead of taking hours and making lots of dust if I do it.
Latest photo
Next day
Did a bit more today got all the wiring off not much left. The nylon chain guide fell apart when I took it off Kawasaki wants almost $60 for just the 1. I'm looking at a Moose Racing replacement.
I am having trouble with the swingarm and triples and the reed valve is stuck pretty well. Ducked out and bought a plastic mallet to try to free the reeds.
Next
Well it's stripped completely except for the headstem ball races and the bellcrank which like the swingarm bolt is being stubborn, unlike the swingarm bolt I can't get anything in there to hit it with. Hopefully soaking overnight in WD-40 helps.
Next
Finally got everything off the bolt finally came out with a few good belts with a chisel I bought to get the headstem bearings out.
LTNS since I sold my KLX I haven't been in here much and yes I know this isn't the KDX section but no-one goes there. Anyway on to my KDX200.
I have a 1999 KDX200 which has not been run for about 5 or 6 years. It's time for me to get it running again.
Got the bike up on the stand and looked it over the frame is missing lots of paint and I'd say the suspension and all the moving parts need some loving so I decided to do a complete teardown and strip back the frame and paint it. This will be a first for me but the KDX is pretty simple so I'm giving it a go. I'll also get the suspension redone for my weight with fresh oil and nitrogen (rear)
Anyway here is the before photo
And where I'm up to before it got too hot in the garage.
Next day
Didn't get time to do anything this morning, family duties, did a little bit this afternoon I think these rubbers need replacing.
Got to this stage, I have to take some off the front then some off the back etc otherwise it wants to fall off the stand. I took the boat anchor (muffler) off and the bike fell forward, fortunately slowly and I was able to catch it. I think I'll have to clamp it to the stand.
The garage got too hot and that drove me back into the air conditioning
Next day
Getting there slowly the air box and shock were a bit of a bitch but finally got them out. The swingarm bolt won't come out left it soaking overnight with WD-40 hopefully it comes out tomorrow. It not seized I can rotate it
Got onto a local bloke who will strip down the frame and swingarm for $100 I think I'll get him to do it instead of taking hours and making lots of dust if I do it.
Latest photo
Next day
Did a bit more today got all the wiring off not much left. The nylon chain guide fell apart when I took it off Kawasaki wants almost $60 for just the 1. I'm looking at a Moose Racing replacement.
I am having trouble with the swingarm and triples and the reed valve is stuck pretty well. Ducked out and bought a plastic mallet to try to free the reeds.
Next
Well it's stripped completely except for the headstem ball races and the bellcrank which like the swingarm bolt is being stubborn, unlike the swingarm bolt I can't get anything in there to hit it with. Hopefully soaking overnight in WD-40 helps.
Next
Finally got everything off the bolt finally came out with a few good belts with a chisel I bought to get the headstem bearings out.
#2
02-08-2017, 07:38 AM
Got lots of farkles to put on the bike when I get it back together like BarkBusters, frame protectors, braided brake lines, Pivot Pegz, Fredette kickstart, Fredette torque ring, FMF muffler (the bike came with an FMF Gnarly chamber).
It needs also new bearings in the suspension, steering head and most likely wheels as well as well as brake pads and new chain and sprockets.
Whew
Oh well you only live once.
It needs also new bearings in the suspension, steering head and most likely wheels as well as well as brake pads and new chain and sprockets.
Whew
Oh well you only live once.
#5
02-08-2017, 03:47 PM
My son-in-law had one for a few years that he would let me use. I could never crank up the ambition to find one and make it street legal (I hate trailers).
#6
02-08-2017, 03:48 PM
#7
02-08-2017, 03:59 PM
The headlight was a $20 Chinese thing from ebay that I was going to use until I could get a stock unit. Then I read about the stock units having problems with some part breaking, and the $20 unit lights up the trail just fine, so I'm keeping it for now.
I picked mine up a few years ago on a Craig's List buy. It's an '03, and had an '03 front tire. Besides the possibly stock tire and other items, I think it didn't have too many hours on it, but some of those hours had been tough. The prior owners, a couple of cousins I like to call "original thinkers," were dip ***** when it came to some maintenance items.
I've since replaced the 220 stock piston with a wiseco (stock 220 piston grenades), boyesen reeds, RB carb and head mods, skid plate, new bars, bearings, seat foam and cover, tires, chain, sprockets, cables, hand guards, FMF desert pipe and a few other items. I want to do the stator rewind/upgrade to get more watts for lights (running the $20 unit on high beam only), and also have an auto clutch that needs to go in.
The folks over here KDXRIDER.NET ? Portal have been very helpful.
I picked mine up a few years ago on a Craig's List buy. It's an '03, and had an '03 front tire. Besides the possibly stock tire and other items, I think it didn't have too many hours on it, but some of those hours had been tough. The prior owners, a couple of cousins I like to call "original thinkers," were dip ***** when it came to some maintenance items.
I've since replaced the 220 stock piston with a wiseco (stock 220 piston grenades), boyesen reeds, RB carb and head mods, skid plate, new bars, bearings, seat foam and cover, tires, chain, sprockets, cables, hand guards, FMF desert pipe and a few other items. I want to do the stator rewind/upgrade to get more watts for lights (running the $20 unit on high beam only), and also have an auto clutch that needs to go in.
The folks over here KDXRIDER.NET ? Portal have been very helpful.
Last edited by IDRIDR; 02-08-2017 at 04:05 PM.
#9
02-08-2017, 06:17 PM
Nice! The KDX is a legendary woods weapon. I love mine.
here's a pic before the duelsport kit.
05 220 was in storage since 2006. I bought it in 2013.
here's a pic before the duelsport kit.
05 220 was in storage since 2006. I bought it in 2013.
Last edited by s10gto; 02-08-2017 at 07:11 PM.
