1991 KDX 200 basket case.

MotoArts · Post by **MotoArts** » 08:29 pm Mar 20 2016

I've successfully used a dremel on needle races in aluminum swingarms.

Grind a "slice" in the (very hard) race the whole width to weaken it, in the direction that the needles lay. I used a rotary file, but a small stone may work but tend to vaporize getting through the hardened metal. Careful not to go the whole way into the aluminum.
Use a small diameter punch & hammer it near the slice to crush the race slightly and unstick it from the swingarm.

Curse words may still happen, but they will be much less severe

Friedom · Post by **Friedom** » 08:31 pm Mar 20 2016

I did that on my steering stem lower race. Worked pretty well!

Edit: I will try not to hijack your void thread anymore. I get notifications every time you post on here, but I don't get them for other threads.. Build on!

Fun Wheel Drive

eprovenzano · Post by **eprovenzano** » 08:37 am Mar 21 2016

Friedom wrote:I did that on my steering stem lower race. Worked pretty well!

Edit: I will try not to hijack your void thread anymore. I get notifications every time you post on here, but I don't get them for other threads.. Build on!

Fun Wheel Drive

Hijack away.... I look forward to your posts...

eprovenzano · Post by **eprovenzano** » 11:28 am Mar 21 2016

Prior to installing the motor, I cleaned the carb again... just because it was in my hands.. I also pulled the reeds to see if all was good... they were in perfect shape. I oiled and installed the new air filter. New swingarm bearing and seals have been ordered along with steering stem bearings. The steering stem bearings had slight play in them... I figure at this stage why not replace if they're suspect... It's coming along...

eprovenzano · Post by **eprovenzano** » 07:47 pm Mar 21 2016

Had a chance to work on the swingarm bearings tonight. I put together a press made out of all-thread, a few sockets, nuts and washers to press out what's left of the old bearings. I had to use a little propane torch to apply some heat and use a little muscle but they did finally come out.

Here what was left of the swingarm bearings. I'll bet they were original.

Yes a few swear words were tossed about, [emoji56] but with a little perseverance and we got em out.

While I wait for the swingarm and steering stem bearings, I'll install the radiators, go through the wiring (making sure all the grounds are solid), tuck the wiring away, finish with the exhaust, and start checking over all the nuts and bolts so I know they're all tight. I also need to look at the choke plunger. When pulled up it does not stay up.

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david · Post by **david** » 10:03 am Mar 23 2016

The choke plunger could be broke. The tread portion recently broke off mine. I got a new one for about $25 then had to work to get the threaded portion out of the carb. Was able to get it done without removing the carb.

eprovenzano · Post by **eprovenzano** » 10:25 am Mar 23 2016

I did some research on the choke plunger, the "cheap" fix is to put a wire tie at the base of the plunger. The plunger is worn, and this helps to engage the action so it stays up when pulled. Here's a thread that spells it out pretty well.
http://162.243.75.126/forums/viewtopic. ... 5&p=145950

david · Post by **david** » 01:53 pm Mar 24 2016

But does it have spring tension holding it down. Mine was actually broken which was not allowing it to seat properly, this in turn will cause it to run rich.

eprovenzano · Post by **eprovenzano** » 07:35 pm Mar 24 2016

I pressed in the swingarm bearing with the same tool I used to remove the old ones. Everything was greased and the collars and seals were installed. I reinstalled the swingarm, rear brake and back tire. Since I was into the grease I also greased the suspension linkage. She's s roller again.... We're getting closer.

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MotoArts · Post by **MotoArts** » 09:12 pm Mar 24 2016

How well did the plastic clean up?

eprovenzano · Post by **eprovenzano** » 09:24 pm Mar 24 2016

Still working on it... That's next on the to do list... Lots of wet sanding

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MotoArts · Post by **MotoArts** » 05:23 pm Mar 25 2016

You gonna ride it with those Peter Fonda/Captain America apehanger bars?

She's lookin' real good, man.

eprovenzano · Post by **eprovenzano** » 05:27 pm Mar 25 2016

MotoArts wrote:You gonna ride it with those Peter Fonda/Captain America apehanger bars?

She's lookin' real good, man.

That just funny.... Why of course I'm going to ride her like that... Lol

eprovenzano · Post by **eprovenzano** » 05:14 pm Mar 26 2016

Great day to pull the plastics out and get busy... I coated em down in paint stripper. It's working , but will take a few coats. I'm also researching a way to weld broken / cracked plastic back together.

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MotoArts · Post by **MotoArts** » 07:47 pm Mar 26 2016

I did the same today to my newly acquired '78 RM250. Side number plates and front fender had been spray bombed but are actually fairly decent OE parts underneath. The orange stuff even lifted the vinyl numbers, but didn't come close to boogering the plastic.
It's worth the time and wait.

eprovenzano · Post by **eprovenzano** » 08:35 pm Mar 26 2016

After a couple of coats of the orange stuff I started to wet sand, mostly to get the rest of the black paint off. I'm happy to report 99% of the black paint off. Most of the plastic will clean up pretty well... Except for one shroud and the rear fender. The shroud has s good sized hole and corner broken off. I have the corner but repairing the hole will be a challenge. The rear fender I received with the bike is steel.. yes steel... I'm going to modify a spare rear fender from my KTM onto the KDX. Just another challenge along the way

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eprovenzano · Post by **eprovenzano** » 10:00 am Mar 31 2016

Oh guys dumb question... but I just don't know the answer... Please remember I did not dismantle the bike so I've been "guessing" where everything goes... I recently realized I used the upper mounting points for the gas tank for the CDI and ground connections... I've looked at the manual but it does not give specific locations where the CDI is to be mounted. I think I have the coil in it's proper location, but with the current location of the CDI (top right side next to the radiator) I don't think I can install the gas tank.

Can someone tell me where their CDI is mounted (or even post a pic or two) and point me to where the bike's wiring grounds should be located...

Much appreciated

david · Post by **david** » 12:14 pm Mar 31 2016

The threaded hole in the frame just below where you have your CDI mounted is where it's supposed to go. If someone doesn't beat me to it, I take a pic when I get home tonight.

Friedom · Post by **Friedom** » 10:12 am Apr 01 2016

I got lucky, there was a dirt outline that matched the shape of the cdi on the frame when I assembled mine. It's the highest hole on the right side of the frame above the right radiator. 6mm.

Edit: but it's not the bracket sticking out of the frame. See picture: (thanks to someone online for image)

Fun Wheel Drive

Friedom · Post by **Friedom** » 10:15 am Apr 01 2016

Looks like you need an exhaust hanger. I just ordered a bunch of them, found em for $13 each. Next best price was around $20. I'll see if I can remember where they came from.

Fun Wheel Drive

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