KDX 200 Rebuild
Discussion
So the nephew gets his first proper bike, a little KDX200 for cutting around the farm and local hills.
But, boys will be boys and not really knowing how to ride, it wasn't long before they were involved in a bike to huge tree interface moment.
Laws of physics being as they are, the winner was a foregone conclusion and was so one sides a contest, even Trump would have called it right.
So, uncles with spanners being as they are, the wreckage now occupies a corner of the garage requiring a bit of a once over.
And it seems not too late. Every bearing is hanging out of its arse, tyres look like superbike slicks and the brakes probably stopped working in the 80's.
God only knows how he got it to go fast enough to crash, the jets are blocked solid with dried fuel and the chain and sprocket are more crooked than a Zimbabwean politician.
Hey ho, God only knows what we'll find in the engine.........but on the upside, it's given me an excuse to buy some new tool toys
But, boys will be boys and not really knowing how to ride, it wasn't long before they were involved in a bike to huge tree interface moment.
Laws of physics being as they are, the winner was a foregone conclusion and was so one sides a contest, even Trump would have called it right.
So, uncles with spanners being as they are, the wreckage now occupies a corner of the garage requiring a bit of a once over.
And it seems not too late. Every bearing is hanging out of its arse, tyres look like superbike slicks and the brakes probably stopped working in the 80's.
God only knows how he got it to go fast enough to crash, the jets are blocked solid with dried fuel and the chain and sprocket are more crooked than a Zimbabwean politician.
Hey ho, God only knows what we'll find in the engine.........but on the upside, it's given me an excuse to buy some new tool toys
Edited by Steve Bass on Thursday 12th November 17:49
MotorsportTom said:
Yay! Another vote for being excited about an SB build thread.
A mate had a Kmx 200 which I believe is almost identical?
It was a good bike but wasn't a patch on my CRM 250
Looking forward to seeing the progress
So found a great resource for parts, orders placed and hopefully start replacing bearings this week.
xstian said:
I like the KDX200, always seemed a good bike. What year is it?
My first bike was a KDX125. It was a lovely bike, but had to sell it to pay for new powervalves for my RGV.
I'm currently rebuilding a CRM250 at the moment, nearly finished just got to paint the tank.
We think it's circa 2004 vintage but has been stood and neglected for a while. My first bike was a KDX125. It was a lovely bike, but had to sell it to pay for new powervalves for my RGV.
I'm currently rebuilding a CRM250 at the moment, nearly finished just got to paint the tank.
Carb is going to need a new pilot jet at least, air filter has been feeding the mice and the head bearings are lubricated with pure mud.
But found a decent resource so orders placed and awaiting the first bits.
Sadly he's destroyed the front plastics and the headlight assembly is not available. So rather than a bad unit we're going to fit a nice simple white mx number board. But on the upside, front mudguards are available so order placed.
Gave the motor a little look over and seems to be relatively ok. We'll see what the compression looks like soon enough though....
Right, apologies for not updating this little thread but things overtook me and I needed to return to work overseas a little sooner than I hoped.
Anyhoo, the 'lil green stink wheel is back on two wheels and rocking the kasbar.
Long story short, the chassis had all the bearings changed out, head races, suspension bearings, wheel bearings the lot. And not before time. On the upside it gave me a great excuse to buy a new set of blind bearing pullers and a few other things.
Front mudguard was replaced with a Polisport Kawasaki item and the destroyed headlight with a generic mx front number board. Looks great I think...
(Nearly) New chain and (brand) new sprocket replaced the old worn out crap.
But the real improvement was In the motor. FMF fatty pipe and airbox snorkel removal with revised pilot and main jets with a 1 notch drop on the needle has it really singing but still a bit fat to be safe. Given the Nephew lives at an elevation 700m below us it should come in nicely on the jetting and goes well enough to pop up the front in 2nd on the pipe... given how much of the work was straightening things out, plastic welding and general cleaning and refurbishing while keeping the budget to a minimum, I'm quite chuffed how the little thing came out....
Wonder how long until I'm fixing it again
Mind you, Xmas is coming up and someone is going to be getting some decent 2T oil, air filter cleaner and oil and some basic sockets and spanners.....
Anyhoo, the 'lil green stink wheel is back on two wheels and rocking the kasbar.
Long story short, the chassis had all the bearings changed out, head races, suspension bearings, wheel bearings the lot. And not before time. On the upside it gave me a great excuse to buy a new set of blind bearing pullers and a few other things.
Front mudguard was replaced with a Polisport Kawasaki item and the destroyed headlight with a generic mx front number board. Looks great I think...
(Nearly) New chain and (brand) new sprocket replaced the old worn out crap.
But the real improvement was In the motor. FMF fatty pipe and airbox snorkel removal with revised pilot and main jets with a 1 notch drop on the needle has it really singing but still a bit fat to be safe. Given the Nephew lives at an elevation 700m below us it should come in nicely on the jetting and goes well enough to pop up the front in 2nd on the pipe... given how much of the work was straightening things out, plastic welding and general cleaning and refurbishing while keeping the budget to a minimum, I'm quite chuffed how the little thing came out....
Wonder how long until I'm fixing it again
Mind you, Xmas is coming up and someone is going to be getting some decent 2T oil, air filter cleaner and oil and some basic sockets and spanners.....
Edited by Steve Bass on Monday 30th November 20:07
Thanks guys,
Still a few little jobs to do but i'll see how he gets on with it first.
Clutch lever needs changing and both levers need shimming as they wobble up & down excessively.
Front brake needs new pads and fluid and possibly a new set of seals as it's as sqishy as SpongeBob Squarepants.... thankfully the rear is 100% and with the better tyres, able ot slow it down sufficiently.
Need ot figure out how to fit a fuel filter. It has new fuel line but the petcock is absurdly long resulting in a short vertical space to the carb inlet so fitting an inlie filter is very tricky. And it needs it, lots of kak in the tank still after some heavy cleaning. I'll see what the carb looks like at the next 'service'
Forks should have new oil as they're probably on the original sand it won't have improved over the years......
next up I need to do some jobs on my Beta 300RR like a new top end and some tidying up.......
Still a few little jobs to do but i'll see how he gets on with it first.
Clutch lever needs changing and both levers need shimming as they wobble up & down excessively.
Front brake needs new pads and fluid and possibly a new set of seals as it's as sqishy as SpongeBob Squarepants.... thankfully the rear is 100% and with the better tyres, able ot slow it down sufficiently.
Need ot figure out how to fit a fuel filter. It has new fuel line but the petcock is absurdly long resulting in a short vertical space to the carb inlet so fitting an inlie filter is very tricky. And it needs it, lots of kak in the tank still after some heavy cleaning. I'll see what the carb looks like at the next 'service'
Forks should have new oil as they're probably on the original sand it won't have improved over the years......
next up I need to do some jobs on my Beta 300RR like a new top end and some tidying up.......
Nice job there Steve.
Is this what you were looking for?
https://www.kawasakipartshouse.com/oemparts/a/kaw/...
Is this what you were looking for?
https://www.kawasakipartshouse.com/oemparts/a/kaw/...
Biker's Nemesis said:
Nice job there Steve.
Is this what you were looking for?
https://www.kawasakipartshouse.com/oemparts/a/kaw/...
oooh you clever sausage Is this what you were looking for?
https://www.kawasakipartshouse.com/oemparts/a/kaw/...
yes, that's the one but it's in the US of A and shipping into SA is a bloody nightmare.
I'll keep that link though, might come in handy.......
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