1987 KDX 200 restore

JohnPainter · Post by **JohnPainter** » 10:41 pm Nov 06 2011

SS109 wrote:Interesting use of Plastidip. I like it!

I've been trying it with other things and exposed to a lot of chemicals and I think the Plastidip will hold up for this application. I've read of others doing similar with old bikes with dry rot on various rubber parts. Well, we shall see.

Post by **dfeckel** » 04:49 pm Nov 09 2011

I was inspired by your restoration, so I went out and got myself a 1987 KDX 200 to rebuild this winter. I'm curious to see how it compares with the E series I occasionally bang around on. I like the digital resettable odometer (I hope the one on my bike still works), the grease fittings on the swingarm pivot and linkage, and the still-operable KIPS valves--just two small ones in the same location as the sub valves in the E and H cylinders. There's no main valve. I also like the big tank, and there's no radiators to bend or shrouds to break. This could be a really cool post-vintage woods bike.

I think I have some old Dirt Rider and Dirt Bike articles that apply to the air-cooled "C" series. I'll try to scan them for us air heads. :)

Post by **dfeckel** » 06:07 pm Nov 09 2011

What technique did you use to get the tank looking so good? Did you use the heat gun like you did with the side panels? You mentioned sandpaper. Can you walk me through your steps?

JohnPainter · Post by **JohnPainter** » 06:06 am Nov 10 2011

[quote="dfeckel"I think I have some old Dirt Rider and Dirt Bike articles that apply to the air-cooled "C" series. I'll try to scan them for us air heads. :)[/quote]

This is where I almost peed my pants. I used to have stacks of both those magazines, wish I had kept them for exactly the same thing! If you have any with articles (particularly on the KDX in those first three years of air cooled KIPS), I'd love to see scans of them!

I know you'll have fun with a rebuild, depending on how you want to do it, it should not cost too much and there's a really rugged old bike in there. I'd love to see what you do, so post away!

JohnPainter · Post by **JohnPainter** » 06:19 am Nov 10 2011

dfeckel wrote: You mentioned sandpaper. Can you walk me through your steps?

It was a four step process: Elbow grease, elbow grease, elbow grease, elbow grease.

Couldn't resist being a smart-ass, because it's very simple, it just takes time. Go get a six pack of what ever and plan to take several days.

No heat guns, I figured high heat and old gas soaked plastic might not be the safest.

I started with scraping (I mean scrape not cut) the white oxidized plastic off the tank with a straight edge razor, so you're down to rough but no oxidization. And then using 400 wet, 600 wet 1000 wet sanding, and then using a regular car buffing wheel for a car, and I did use a polishing paste.

If you have an original tank like mine (any plastic I'm finding) almost inevitably any former stickers will leave a faint shadow all the way through the plastic. I'd read somewhere that's the effect of the adhesive over many years. You won't be able to get rid of that because it's so deep, so just plan to put a new tank sticker over it or learn to live with it. Good luck!

Post by **dfeckel** » 09:48 am Nov 10 2011

Thanks for the info. It's good to know that the original green is still in there. I did notice the ghost of the original stickers in your pictures and wondered what that was all about.

I'll dig out those magazine articles and break some copyright laws this weekend :)

Post by **dfeckel** » 11:15 pm Nov 10 2011

I scanned the first air-cooled KDX article tonight. It's over in Memory Lane. Enjoy!
http://kdxrider.net/forums/viewtopic.ph ... highlight=

JohnPainter · Post by **JohnPainter** » 11:04 am Nov 11 2011

dfeckel wrote:I scanned the first air-cooled KDX article tonight. It's over in Memory Lane. Enjoy!
http://kdxrider.net/forums/viewtopic.ph ... highlight=

Wow, thanks! I am really thankful to read up on those twenty ways to improve the KDX.

I love air cooled engines so all these tweaks are priceless to read up on.

JohnPainter · Post by **JohnPainter** » 08:48 am Nov 12 2011

Hmmmm, I've been wondering if there's another set up for winter riding other than studded knobbies, not my KDX but gets one thinking

rbates9 · Post by **rbates9** » 04:01 pm Nov 12 2011

That looks pretty cool! What did they make it out of? Is there a ski up front?

Fletch · Post by **Fletch** » 08:15 pm Nov 12 2011

there's tread marks under the bike so I'm thinking a tire

JohnPainter · Post by **JohnPainter** » 08:32 am Nov 13 2011

rbates9 wrote:That looks pretty cool! What did they make it out of? Is there a ski up front?

There was a tire up front, crazy hu, but shows a KDX can still be an innovative platform. Well off to cut some gasket.

Post by **dfeckel** » 04:59 pm Dec 19 2011

Here's a question--What are you doing to replace your worn linkage bearings? I'm especially interested in the spherical bearings of the pushrod that attaches to the swingarm. Have you had any luck locating replacements for those? My '87 has a VERY worn upper spherical bearing, as well as the bolt which goes through it. Bike Bandit is showing those parts no longer available.

david · Post by **david** » 07:21 pm Dec 19 2011

dfeckel- Service Honda shows them still available @ $67.14 each. #59266-1056. The bolt is discontinued but you should be able to use a regular 14X50mm bolt and drill a couple of holes for a grease fitting.
Or for $41, maybe these are still good. http://www.ebay.com/itm/Kawasaki-KDX200 ... m=12065562

blanc · Post by **blanc** » 11:49 am Feb 03 2012

Well done

Antoniollosa · Post by **Antoniollosa** » 04:43 pm Nov 29 2012

JohnPainter wrote:Is Jeff Fredette a God?

I just got my "new" flywheel and rebuilt stator for my '87 KDX 200 from FRP, my engine is apart, but wow, it's a work of beauty and I can see right off this flywheel will not have the magnets come apart.

hello my name is Antonio and I have a KDX 200 1987, if you do not have the exact mediated internal and external flywheel, the previous mechanical flywheel broke and lost ... that could put flywheel or adapt a since in Peru apparently not meeting told me that he had a indian nippon NFP5110 :/

Greetings ..

Antoniollosa · Post by **Antoniollosa** » 06:22 pm Nov 29 2012

hello my name is Antonio and I have a KDX 200 1987, if you do not have the exact mediated internal and external flywheel, the previous mechanical flywheel broke and lost ... that could put flywheel or adapt a since in Peru apparently not meeting told me that he had a indian nippon NFP5110 :/

Greetings ....

kawagumby · Post by **kawagumby** » 07:42 pm Nov 29 2012

This might help you http://www.kdxrider.net/forums/viewtopi ... 19&t=12423

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