1999 KDX 200 build :)

superman27e · Post by **superman27e** » 01:21 pm Aug 21 2014

After buying my KDX 200, I realized that maybe I jumped the gun and purchased the first one that was available. The bike ran like crap, had every problem a bike can have, and on top of all that, I think I paid too much for it. :P

This is what I started with. Very clapped out KDX, haha.

I don't have many pictures of what I've done so far, but I have a list.

New piston
New clutch frictions, steels, and cable
New grips
New rear tire
New exhaust spring (WoooHoo)
New IMS shifter
New packing
And a few other things that I can't think of right now

The piston was far gone, but the jug looked great, thank god! The engine got a deep clean before it was put back on the bike.

The swingarm on this thing was ugly as sin from where the last owner tried to spray paint it, but didn't even at least wipe it down first. So I took some paint remover and sandpaper and went to town all the up to 2000 grit. Looks a lot better. Checked all the bearings and what not, and they were fine after a nice cleaning.

Also shined up a few other parts.

Right now I'm waiting until next month to get the rest of the parts. I have counter shaft seal, water pump seal, ect on the way now, so right now, this is how she sits.

I managed to get most of that black spray paint off of the engine since this picture, so it looks a good bit better.

And this is the rest of her.

Things to come next month

All new plastics
New handle bar with hand guards
New chain
New radiator guard screens
Graphics
One of those fancy looking headlights that you strap onto the forks
New front tire
Seat cover. Because tape just doesn't work?
FMF woods pipe
And a few other things

Tedh98 · Post by **Tedh98** » 02:55 pm Aug 21 2014

I totally forgot that you started with the red KDX!

superman27e · Post by **superman27e** » 04:09 pm Aug 21 2014

Yea, man. My awesome wife scrapped all the red off of the plastics and tank. Then she shined up the rims and forks :)

Fitterman24 · Post by **Fitterman24** » 04:48 pm Aug 21 2014

I re-did mine last winter. Sandblasted the frame and used self etching primer before Duplicolor Grabber Green paint. If I had to do it all over again....and I probably will the winter after this....I'd have spent a bit more and went with powder coating. I have not been happy with how the paint has stayed on in places. I prepped good and let it cure for almost a month before I started assembly. Now I understand why some guys go the powder coating path.

superman27e · Post by **superman27e** » 05:18 pm Aug 21 2014

How much would it be to powder coat the frame?

diymirage · Post by **diymirage** » 05:39 pm Aug 21 2014

superman27e wrote:I think I started a thread on it before, but can't find it. So here's my build thread.

if you did it is one of these ;)

http://www.kdxrider.net/forums/search.p ... mit=Search

don't forget to get some socks for those forks or youll be changing out seals every other ride

superman27e · Post by **superman27e** » 08:23 pm Dec 17 2014

Could I use some clear coat to go over the swing arm so it keeps the shine? It's just bare aluminum right now.

6 Riders · Post by **6 Riders** » 09:15 pm Dec 17 2014

superman27e wrote:Could I use some clear coat to go over the swing arm so it keeps the shine? It's just bare aluminum right now.

I polished mine, didn't bother w/clear since it is aluminum.

superman27e · Post by **superman27e** » 10:24 pm Dec 17 2014

How's it holding up? Is the maintenance difficult?

6 Riders · Post by **6 Riders** » 11:56 pm Dec 17 2014

I don't need to do anything but wash it, if that's what you are asking. I was told it might turn a yellow/gold color. If it ever does, I'll just run a polishing ball over it.

superman27e · Post by **superman27e** » 02:00 am Dec 18 2014

6 Riders wrote:I don't need to do anything but wash it, if that's what you are asking. I was told it might turn a yellow/gold color. If it ever does, I'll just run a polishing ball over it.

10-4 Thanks, buddy.

6 Riders · Post by **6 Riders** » 02:42 am Dec 18 2014

Thinking about it, I didn't really polish it....I just took it down to bare metal. I left the brushed look on it.

Tioli · Post by **Tioli** » 07:20 am Dec 20 2014

I use a product in a spray can called Penetrol. It's claim to fame is for using on rusty parts you can't get to. It's 4 x thiner than water and is suposed to penetrate rust and creveses and lock it up (no air). It's oil based and dries clear with a nice shine. Can also be painted over.
I sanded and polished my swing arm sides on a bench buffer then washed the polish off with kero and spraied. It stickes fine you can see the results by following the link in my post in hybrids.
I'm in AUS and presume you have it in US.

superman27e · Post by **superman27e** » 01:32 pm Dec 28 2014

Update:

I order a water pump mechanical seal
Renthal CR high bends
Scott grips
Seat cover
Front tire
Right side engine cover gasket
And front and back brakes

Too excited!!!!!

superman27e · Post by **superman27e** » 04:25 pm Jan 01 2015

Little update:

Got my brakes yesterday, so I cleaned up the caliper, brake parts, put new fluid in, ect. Also got the new seat cover on and have some left over material to make another seat cover! It's crazy what a new seat cover can do for looks.

I get my handle bars and front tire tomorrow, so I'll be posting another update then. Also have the water pump mechanical seal on the way as well.

Here is what she looks like today.

Getting closer

superman27e · Post by **superman27e** » 02:59 am Jan 30 2015

What's going on, guys? Been a while since I've updated this thread because of classes and what not. But, since my last post I've ordered the full plastic kit from UFO, full graphics, a front number plate, radiator screen protectors, frame guards, no toil air filter, and seal savers.

I got the all green plastics, so that includes green side panels as well. Should look nice with the black and green monster graphics and my black renthal bars.

Everything will arrive before February 5th except for the seal savers. Those are coming from Australia. I'll post some pictures once everything arrives and I install everything. Super excited!

Sullyfam · Post by **Sullyfam** » 10:54 am Jan 30 2015

[emoji106]

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JFortner5 · Post by **JFortner5** » 12:03 pm Jan 30 2015

Sullyfam wrote:[emoji106]

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X2. Looks like it's coming right along. I'm sure all the work will be well worth it when you take it out for the first ride.

Heck half the fun is working on them anyway!

superman27e · Post by **superman27e** » 10:49 pm Jan 30 2015

I got a nice surprise in the main today. I got my plastics, air filter, and graphics today. I just ordered everything 2 days ago, so I wasn't really expecting anything for a few more days. I put everything on and I'm very happy with the way it looks! :)

Just waiting on seal savers, front number plate, frame guards and something else I can't remember for the life of me, haha.

Anyways, here's another before picture, a picture of it the day I got it, and where I'm at now as far as progress.

Before -

Little brother riding it. :P

After -

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