My old girl

[cmarico]

I've got a 1993 KDX200E here in Australia, well, at least I believe it is!

I seized her up a bit over a year ago, and the poor girl sat in the shed ever since. I finally got off my ass, whipped the engine off, and got the head and barrel off.

Nice chunk missing out the side of the piston. Bugger. Bore looks ok, no gouging, smooth all around. A little bit of a lip near the very top of the bore, not sure if this is normal?

Crank is seized up though. Guessing the missing bit of my piston has fallen down in there and gotten jammed into something. Here's to hoping it's just wedged itself somewhere, and that with a bit of work I'll be able to unwedge it with minimal damage to the bottom end. I won't know until I split the cases which I am yet to do. So, here's to hoping, otherwise it may be the end of this old girl (at least given the prices/quote I've received).

Also, my KIPS valves are destroyed :(

2 kips valves $110
piston, rings, $160
gaskets, $100
conrod/crank kit $165 plus $100 labour for fitting/balancing
main bearing kit, $60
bore/sleeve the cylinder, $400

I'm not really sure how much of this needs to be done, I'll get some pictures in the next few days when I split the case and hopefully can get this old girl running again for not too many coins (have a baby on the way, so trying to do this myself and keep it cheap, otherwise I'll probably have to get rid of it).

Sadface.

[KDXGarage]

Good luck on the rebuild.

[Julien D]

That's a lot of money for a replate. How bout some pics of the cylinder? If it's usable, that could save you a good bit. Also the crank rebuild seems pretty darn high. The crank itself should be fine. A con rod kit should run you about 70 on eBay, and I would expect 50 or so for labor. Of course, your prices are probably AUD, so I don't know how that translates. But all in all, a top and bottom end rebuild should be possible for about 600 USD, and that's damn near everything if you can do most of the work yourself.

[cmarico]

Hey guys, thanks for the replies.

It's all speculation at this stage, until I pull split the cases. I'm really hoping that my missing bit of piston has just gotten wedged between something, and hoping that it's softer than what it's gotten wedged into! Would be great to be able to pull that out, flush any fragments, replace kips, and basically do a top end from there. Here's to hoping! Once I've got it all apart, will hopefully have more news on prices.

[sarrant]

That's a lot of money for a replate.

I am assuming the numbers are Aussie dollars. Also, cost of everything is pretty high there.