bringing a 30yr old KDX back to life

[dangerous]

well... goes like this, scored a 89 KDX200 of a mate, he is the 2nd owner and didn't use it much, in fact its sat dormant for several years 3-5 since it was last started... soooo I was expecting a few issues, like on fire up crank seals etc would or could tear open, and id be in for a major rebuild which I wouldn't be able to afford. But as luck might have it I don't think there are any engine or transmission issues.

The water pipes were all rock solid and crunchy cables seized and the carb had not but a film but caked in a black tar. Carbs took three cleans to get right, the radiator didn't look to bad but fuck me there was a lot of dry shit in the hoses, so several flushes and replacements they are better but i'm still flushing the shit out.
On fire up and like all good strokers it did start but was not happy, the exhaust was blocked so I removed the center baffle with the glass in it so it could breath, hiffed the rest in the brazer and cooked up the oil.

so I should have taken photos as I went but was all to excited as Id been hassling this mate for a long time.. hey my boy victorious has a KX80 so i wanted to rip the local river bed up with him.
The bike when it was new had both guards and head light removed, the side covers were covered in clear film.
After the first hoon (photos with the number 38 on I replaced all the used plastics with the original, the side covers cleaned up awesome with a lot of elbow grease, and under neith 30yrs of shit the original number boards were still there and scrubbed up mint.

The bike slowly started reving beter and beter, I was thinking mean its all gonna be ok... but noooo... the radiator started pressurising back into the catch bottle so i knew all wasent well.
took the clutch cover case off which I should have done earlier and found the water pump impeller had rusted away completely... gone dissolved unbelievable, even the bolt head holding it on was history.. so i'm kinda hoping I hadent cooked its self as id been giving it the berries to clear it out.
seems ya cant get 30yr old parts anymore stupid kawka but hey after searching the globe I think I have found a new shaft and impeller from a local shop bailey MC.

Right photos in next post and my thoughts on my 1st trail bike... stupid things.

[dangerous]

Having never had a dirt bike, I was kinda excited in all, figered can't be to different to a road bike.
Well... Down the the river I went with my kid kber victorious and had a play... WTF is this shit, it was like riding a jelly fish on P, bugger me it was like every bearing and seal was shaged worse than a Manchester street hooker...
So asked SVboy for some pointers... All he did was nod and say "if in doubt... Power out"
OK... I'll try that, so I'm having a few doubts on the corners, POWERED Out, ended up going straight and into the scrub.
Booting along a stop bank... Had a doubt... POWERED Out ended up down the bank on my arse with my 9yr old on his KX shaking his head at me... Fuck this thing is fun love strokes... But alas its all turned turtle litrely it's upside down on the garage floor awaiting internal organs, that don't exist...

So heres a few pics, I have some questions for anyone out there that know the kdx, cos it's all new to me.

re pics FAIL.. will try tomorow

[dangerous]

From the start to now

[dangerous]

Right come on kdx gurus... Note the drain area is now partly blocked of with my helicoil... Well, if you remove the bolt and look up its orifice it goes into a open area... Is that the gear box in there.. So the box drains out... But how the bloody hell does the oil get from the clutch side to the gears???

[onearmedbandit]

Right come on kdx gurus... Note the drain area is now partly blocked of with my helicoil... Well, if you remove the bolt and look up its orifice it goes into a open area... Is that the gear box in there.. So the box drains out... But how the bloody hell does the oil get from the clutch side to the gears???

If this is the same as yours (visually it checks out) there is a hole in the c/case above the centre bearing.

https://www.ebay.com/p/1372642089

Ron Ayers can be a handy site to spot stuff but wrong side of the crankcase was shown.

https://www.ronayers.com/oemparts/l/kaw/500ae315f8700209983b4f3f/1989-kdx200-kdx200-e1-parts

[dangerous]

If this is the same as yours

Hey man... Well no, even tho it says 89... I have been told they up to 93 are the same... But no the pump shafts differ as I have found out, mine looks nothing like your link, that looks 94 on... Buggered if I know

Re oil getting from the clutch side to the box, only hole I can see is the wee bugger under that spring...
I was worried that it back flows up the drain hole whis I now have a helecoil blocking

[sugilite]

fucken hell, a great thread started on KB< not seen one of these for a while. It's even about motorbikes n shit. :Punk:
I got nuthin to help ya right now, but super happy you posting this :yes:

[sugilite]

Could this stuff be useful?
https://www.ebay.com/itm/Kawasaki-KDX-200-1989-1994-Engine-Rebuild-Kit-Con-Rod-Mains-Piston-Gaskets-Seals/183805479308
https://www.ebay.ie/itm/1994-KAWASAKI-KDX-200-ENGINE-WATER-PUMP-IMPELLER-W-HOUSING-26939-/124036402312?hash=item1ce1254c88
https://www.ebay.com/itm/ProX-Kawasaki-KDX200-KDX-200-1989-1994-Water-Pump-Repair-Kit-33-57-4319/332235259665?hash=item4d5ac3bf11:g:Jm0AAOSwkABdef8 y

[dangerous]

fucken hell, a great thread started on KB< not seen one of these for a while. It's even about motorbikes n shit. :Punk:
I got nuthin to help ya right now, but super happy you posting this :yes:

and its good to still see 15yr old names pop up here to... cos we seem to be nodding off a bit these days.

[SVboy]

Looks like there are two holes at the top of the casing with two dams that feed oil into the gearbox when You fill it. Would your issue be the helicoil blocking oil from draining from the clutch side when you change it? How deep is the sump plug? If it is shallow, can you cross drill the helicoil. Yikes!

[F5 Dave]

Mate I was late back into dirtbike at 30 having had a PE175 stolen at 16 only ridden twice.

Best thing I've done. Only live once. If you fall over 4k find yourself a GasGas 200. Or 250 or 300. Difference is exceptional and enjoyable 150% more.

Live once.

[dangerous]

righ ohhh... got me referb kit today so fitted up new bearings and gaskets.. the pump seal tho was diferent to the one i took out, and after I fitted it noticed there was a second part to it, fucked if I know were thats ment to go...

well.. helecoil has worked no leaks, same with the water...50m up the road later, water in the oil, that quick.. fuck, will strip down again next week.


Mate I was late back into dirtbike at 30 having had a PE175 stolen at 16 only ridden twice.

Best thing I've done. Only live once. If you fall over 4k find yourself a GasGas 200. Or 250 or 300. Difference is exceptional and enjoyable 150% more.

Live once.

mates got a husky wr360... you would not think its a stroker, torque is amazing.

Looks like there are two holes at the top of the casing with two dams that feed oil into the gearbox when You fill it. Would your issue be the helicoil blocking oil from draining from the clutch side when you change it? How deep is the sump plug? If it is shallow, can you cross drill the helicoil. Yikes!

are you refering to the post above of the casing... nothing like mine.
but hey filled it up to day and no worries.. and no leaks.

[F5 Dave]

My 300 has amazing low end power followed by great midrange and a big zing at the top. You would not think it is a foulstroke as it is so much better and of course lighter.
And sounds better.

[dangerous]

Out for a hoon with the boy...

[scott411]

externally the KDX looks real good,

[dangerous]

OK, so after that hoon with the boy the pump seal failed again, so I brought another new one and it seems to be holding and the water system isn't pressurising so bugger it time for new tires and uni filter... tomorrow will be a big test day... My first organised trail ride... Bets are on as to if I break... The bike breaks... Or both...

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[F5 Dave]

Cool stuff.

Bit of rain here overnight and my tyres are a bit shagged. Holding out fitting replacement in garage for a particular ride. Might go sharpen these again with the flat blade on the renovator tool.

[george formby]

Cool stuff.

Bit of rain here overnight and my tyres are a bit shagged. Holding out fitting replacement in garage for a particular ride. Might go sharpen these again with the flat blade on the renovator tool.



You do that to? Nice.

[Kickaha]

tomorrow will be a big test day... My first organised trail ride...
Mt Torleese ?

I'll be doing on this manky old shitter
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[dangerous]

Mt Torleese ?

I'll be doing on this manky old shitter


that is farking tidy... and very cool...

see ya there, ill be with SVboy...

[F5 Dave]

Hey Kick. Wanted one of those back in the day

[Kickaha]

Hey Kick. Wanted one of those back in the day

I get a lot of that

I have another one to put together plus a couple of 175

It's been 12-14 years since I rode this one and took it apart to rebuild, it's had a small shakedown run so tomorrow is a bit of a test for it

[dangerous]

OK, My first organised trail ride... Bets are on as to if I break... The bike breaks... Or both...

shove ya FARKING ENDURO track right up were the sun dont shine...

yeah well detouring onto the enduro corse was bit of a balls up, one of the guys said the 2nd enduro is ok give it a spin... yeah well he missed the 2nd and was talking about the 3rd corse... fuck me it was a hiking track and at that ya be on all fours climbing up n down, shit sakes it would be a mission for a trials bike with the worlds #1 on it... but hey beat SVboy through it didn't help he went the wrong way and ended up down a crevasse LOL... silly old bugger, naaaa, it was awesome, but i wont rush into another enduro... as for the trail ride... my 1st time on a chook chaser other than a few test rides up the local river... bloody magic, a bit of everything and scenery you would never usually get to see...
Only issue i had was the big bore boys passing on heavy stones and flicking fist sized rocks an my knees and lid, fucking hurt ya knobs...so whens the next trail ride SV...
ohh and Kickaha, ask diesel pig if he need a lowering kit, LOL... awesome dismount at the top... and diesel thanks for the "ya not my biggest fan, but don't do the enduro" speach, why didn't I listen LOL

was told by a bike following that the kdx smelt like it was burning box oil... bugger watch this space for a rebuild as the crank seals are replaced :rolleyes:

[F5 Dave]

Can't post pics from this phone but jezuz but fuking Krist it was a great ride today..out to the coast. Fantastic

[Kickaha]

but don't do the enduro" speach, why didn't I listen LOL

Because you're a dumb cunt

[SVboy]

Because you're a dumb cunt

That it was gorgeous Kickaha. D did bloody well. That second enduro section was a bridge too far for me.... but my mighty KDX did not miss a beat.

[Kickaha]

That it was gorgeous Kickaha. D did bloody well. That second enduro section was a bridge too far for me.... but my mighty KDX did not miss a beat.
I've found the enduro sections a bit hit and miss as to how hard they are so I just don't bother with them anymore, although I actually found the 200 a bit lighter and more manageable than my 250 so maybe next time

[Kickaha]

Diesel Pig was on this thing, which having ridden it is a bit of a weapon but needs a little work, of course I smashed him on the mighty IT200 especially downhill
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