New to me 89 KDX200. Another rebuild story...

[skyriver]

Alright guys. She's finally in test ride shape. Actually rode it in the cul-de-sac tonight and the clutch works. Runs spot on. No bottom-end stumble or anything. Still has an issue with getting too much so either float issue or petcock. I installed the petcock re-build kit, but I think the reserve tube is completely missing. I shifted her just between 1st and 2nd and no issues. Brakes need a little more grab, but back is still rusty and the front had some WD-40 on it.
A trail bomb close to the truck is the next step. My son started it twice easily in his basketball shoes so he's all smiles. Her she is about an hour ago...


And another

[TrophyHunter]

Congrats. Looks trail ready - except the WD40 braking.

[Thack]

Looks nice! Let us know how it is on the trails.

[skyriver]

Update. Still no test ride!! other than the cul-de-sac. Been really busy with work and kid's sports.
I have found a few things. Not huge, but nickel and dime stuff.
Fork seals were leaky and the base 14mm allen doesn't want to budge so I did the sandpaper trick that Wibbens has posted. I used 600 instead of 320 because I had 600 on hand. We'll see if that works. So one fork is ready to go with left over (half 15 wt and half 5 wt) fork oil filled to 125 mm. The manual says 138-142mm of 10wt, but I read somewhere guys really like 125mm. I have to buy more oil for the other fork. I have spare seals if these still leak too much. Just have to attack that 14mm base plug harder next time. Impact for sure. Hitting it hard with the bike strapped down didn't do a thing besides tearing up the edges a bit.

Front brake pads were toast. New ones are on the way. I should have inspected them better to start. I thought there was some pad left, but upon a better look they were metal to metal on one side. Maybe that's why I couldn't stop!

Test riding for sure on Tuesday no matter if I have a front brake or not. I have an extra day off so going for it. Going to a local riding area that has a parking lot next to a big squid area so I can ride close to the truck in case something breaks. I can also have another bike in the truck and not get it stolen. My KTM300 hasn't been out for close to 2 months so will run it too. It will be nice to finally open it up on the KDX to see how it truly runs. Just from putting around the cul-de-sac I can tell it probably needs the air screw out, but I'd rather have it rich to start to keep that piston lubed. Some bumps, whoops and small jumps should tell me if the float is behaving as well. I plan on taking some GoPro video so I can review how she ran. It might help with any jetting issues. If I get anything insteresting I'll post it.

p.s. Anyone need a 1988 KX125? Freed up the pistion last week. It was rusted stuck just around the top of the piston. Piston and cylinder look good actually. Idiot PO let water get in there so I think the crank has quite a bit of rust. I know I could get it to run, but I don't feel like splitting the case and putting $$ into it. I'd rather just sell whole or part out.

[skyriver]

Ok guys, finally got the KDX out today. I now understand all the comments about smooth and easy to ride. This thing is a peach! Buttery smooth, not too much power, but enough. Only thing I can't stand is the mini-bike bars. And the funky top-clamp that puts them in my lap, but the bike is really nice. It will be perfect for my kid. It ran really well no matter what I did to it. I didn't have any big hills, but I did purposely go up a small climb in 3rd to see if it could pull it with my 215+gear and it did great. Not the bottom that my 300 has, but plenty, especially for my 150 lb kid. He was so jealous! We'll get him out next time.
Here's a video of the KDX, mostly hitting small whoops in the "squid area" of Tahuya. Also a road where I hit 6th wide open and it never complained. Not sure if I did the video post correctly. We'll see.
[youtube][/youtube]

The funny part was riding my 300 after riding the KDX. Man, my bike is a fire-breathing dragon that I was affraid of for a few minutes before I got used to the power and suspension again. I'll have to say the KDX turned on the loose stuff better than the KTM today. I know I'm still faster on the KTM, but the KDX was easier. Very happy with the $500 green bike.

[SS109]

Your vid is listed as "private". You'll need to change that if you want to share it with us!

Don't sell the little 200 short. Just about all my buds ride KTM's. The one 300xc in our group, well, I was always on his butt through the tight stuff. The only time he could pull away was in the straighter open sections. As soon as we started hitting the twisties again I would be right back on him! This was on an old, abused, and ready to be rebuilt '90 200. The KDX just out handles the 300 in tight stuff and has the ability to apply the power to the ground easier since there is less of it. I know the old KDX's has shocked more than a few 250/300 owners out there!

[skyriver]

I knew I'd probably screw up the video. Ok, changed it to unlisted, but that still let's me share it. Maybe better now.

And I agree that the KDX could keep up in the twisties. Of course, it's always the rider that decides that for the most part. I have riding buddies that whip me on their KX100s! Of course, they're A and AA enduro guys so they're good in the tight stuff no matter what they ride. Our KDX is still too small for me right now. It doesn't feel full sized to me since the bars are way back. And, to be fair, I'm 6'4". My arse was hitting the back fender through those whoops so I definitely need the cockpit a little longer than most. The KTM fits me very well. I was very impressed how well the KDX turned. The thing loves to turn! I actually do need to take a link out of my KTM chain as the wheelbase is getting a bit long. All things considered though, I'll never sell the KDX short! My son has no excuses and shouldn't need another bike until he has the $$ and/or the will to buy himself something else.

[rbates9]

I actually do need to take a link out of my KTM chain as the wheelbase is getting a bit long.

[skyriver]

Sold the KX for $100!! It will go into 95+ top clamp, front numberplate/headlight and hand guards.

[skyriver]

Ok, it feels like a real bike now!

95 and newer top clamp with Pro Tapers

[skyriver]

UPDATE: Shock seal blew. Just got done rebuilding it myself thanks to help from the internet including this site. If you ever thought of doing this yourself you can. It does take some patience. I had to buy a new bumpstop as the old one was nearly gone. I also had to buy a new seal head assembly. Some advice here....Don't try to figure out what parts you need from the Kawasaki site. They don't even expand simple parts like the bumpstop. Just search KDX seal head assembly on ebay and you'll find a few of them for $35-45. Done deal. And I have had decent luck with Race Tech before, but they cost me a ride on this one. I ordered a bumpstop from them and they took payment, but didn't mention the part was on back order. I finally called a few days before our planned ride and found out it was back ordered. I was not pleased. So I drove 10-12 miles to Devol like I should have in the first place and bought one for the same price, less the shipping.
Also, just google KYB shock rebuild and the second link (iriders I think) has a great procedure to follow. The secret to bleeding (besides the safety wire trick that I actually don't like) is quick hard pressure down and then slow stopping pressure back up. It takes a few "pops" with a rubber mallet too to knock all the air out of the shims. Anyway, I just need a shot of Nitro that I can get for some beers from a buddy or $10 at Devol. Either way, the hard part is over. I'll slap the bike back together tomorrow and we'll be riding Saturday and Sunday!

Keep it rubber side down...

[skyriver]

Hi guys,
Been a while. KDX has been working well for my oldest son without any $$ put into it since last post. It has had the dreaded float level issue of pissing gas. Cost us major miles on one trip. I've adjusted to way out of spec at 20mm or so and it finally only leaks if the bike leaned over past 45 degrees. Put a new float needle in it as well so should be good.
Finally spent a little $ on it again and got some new grips, hand guards, KX rear fender and front plate. Shroud KDX stickers are in the mail. She's looking a little better.

Saving this thing from the junk heap has been very rewarding. Thanks again for all the info on this forum. It's helped a lot with the green machine.

[Andy_H]

I'm in the process of an 89 restore project and found this thread very useful. I've had my bike since 1990 and rode many enduros here in the UK. The KDX is a great bike and your son will love it. I'm struggling with finding the correct paint colour over here, I need the swing arm and frame paint codes, powder coat or paint. They want a kings ransom in some places.

Make sure the air filter is cleaned and the fuel is not too old as this helps with the spooge build up. I found running 40/1 max was a good balance of protection and performance.

I will have to refurbish my rear shock, thanks for the tips as I am not looking forward to that. The stock front forks are not that good, too soft for high speed, can throw you off (scars to prove it) on certan terrain.

Enjoy!