A few questions about my 94 kdx200

Post by **KDXGarage** » 12:38 pm May 26 2016

Get a rod kit, main bearings and seals.

It looks like someone ran it with no filter, a non-oiled filter or some way it ate dirt.

ubareddition · Post by **ubareddition** » 04:43 pm May 26 2016

Should i think about crankshaft ballancing? Still trying to find a decent priced kit that just sells all the seals and gaskets for the whole engine.

ubareddition · Post by **ubareddition** » 08:01 pm May 26 2016

Any suggestions for removing the head studs? I tried the double nut trick and it did nothing.

Dekon · Post by **Dekon** » 08:15 pm May 26 2016

I would soak them with your favorite brand of penetrating oil. You might also be able to heat them with a torch, but I'm sure if you should do that on the cylinder; I'm sure others will chime in.

ubareddition · Post by **ubareddition** » 08:28 am May 27 2016

Ive got it soaking now while im at work. Hopefully i can get them out later.

I feel like im asking alot of questions. But i have a few more. What is this thing? Is it supposed to be bolted to something. I found it just sitting there loose when i took off the seat.

Dekon · Post by **Dekon** » 08:59 am May 27 2016

That's the voltage regulator. It should be bolted to the top of the air box cover. Don't worry about all the questions, that's what this site is for. It definitely helped me with my build.

ubareddition · Post by **ubareddition** » 09:12 am May 27 2016

So it doesnt have to be bolted to the frame to provide a ground?

Dekon · Post by **Dekon** » 10:08 am May 27 2016

Nope.

ubareddition · Post by **ubareddition** » 03:44 pm May 28 2016

Here heres the plan going forward with the bike whats been done and needs to be done. In no particular order.

Pipe: fmf gold series gnarly pipe installed (previous owner) needs to be cleaned up a bit and the pipe protector needs to be spun a bit to face the correct direction.

Silencer/spark arrestor. It was loose leaking missing the 3 bolts at the back completely filled with carbon. I have no idea how the bike even ran with all the crap in it. Needs to be cleaned, repacked and new replacement bolts installed. Its also missing some mounting hardware. Either from being crashed or something. Needs new hardware so its not flopping around.

Front brake lever: needs replacement. Only big enough to get 2 fingers on.

Headlight: i have a set of HID lights i think will fit. May need slight modification to work.

Front shocks: need to be rebuilt. new fork oil....seals and adjusted.

Front wheel bearings: one of the first things i did when i got the bike. They were very bad. Bearing connection brand i beleive. Previous owner new they were bad cause the new bearings came with the bike.

Odometer cable: was broken since i got the bike and who knows how long before that. I would like to get it fixed so i can start to see how many mpg im getting.

Front brake pads: almost completely gone. Need to be replaced. Check caliper for signs of wear and rebuild accordingly. Adjustment needed as well.

Rear shock: according to the previous owner was rebuild recently and recharged.

Rear linkage: also rebuilt and parts replaced by previous owner.

Rear wheel bearings: need to be replaced asap.

Chain: was replaced right before i bought the bike. Tension may need adjustment. Maybe some lube and wax too.

Rear brake pads: need replacement, inspect caliper, grease, adjustment.

Rear brake light: need to find what parts im missing and purchase them. Install. Would like to find a bright LED version to put in.

Stator: would like to modify for more power for lights for night time riding.

Lighting/ignition coil: look for posible upgrades.

Head: finish removing headstuds and ship off for replating and ect. Might do some light port and polish work before i send it off just to clean up some casting marks and improve flow.

Carb: needs to be cleaned real good and packaged up to ship to ron along with the top of my head.

Bottom end: need to source parts for rebuild and purchase. Need to find out if crank should be ballanced or lightened prior to rebuild. Also is my connecting rod OK or do i have to replace that too?

Transmission: needs to be flushed a few times once the bike is running. Maybe adjust the clutch and think about replacing sometime.

Engine: would like to get a kit of all the engine seals and gaskets and just go ahead and replace them while im waiting on my machine work. Radiators and such need to be flushed to get oil out.

Wiring: looks like the previous owner messed with the lighting a bit. Especially in tbe headlight. It needs to be redone. Bare wires are not acceptable. While im doing that id like to install a keyed ignition switch to prevent/deter/slow theft.

Hand gaurds: mine were non existent pretty much. Id like to fab a set like the ones my buddy has on his 220. They seem super easy to build.

Kickstand: would like to fab a good kickstand.

Gas cap: had a large crack in it. Needs to be replaced.

Throttle: sticks a little. Needs to be cleaned and greased

Air filter: need to evaluate its effectiveness in light of all the dammage to cylinder walls and piston and possibly upgrade.

Man that should keep me busy for a while.

6 Riders · Post by **6 Riders** » 05:36 pm May 28 2016

I like the MSR lever set with the rubber inserts. You can find the Winderosa oil seal set for these bikes in EBay.
Buy a few good air filters, clean and oil them at once, this way you always have a fresh one ready. And change them often!
New throttle tubes available for $8. Just get one, or better yet, put a kx throttle on.
You will have to have 12 volt DC to use HID lights, I think a good size battery as well. Look into LEDs, you'll need DC power, but less of it. The rear tail light is not a brake light, but can be made into one. PM me for the light assembly.

ubareddition · Post by **ubareddition** » 06:02 pm May 28 2016

http://www.ebay.com/itm/230985091146 i found this one

http://www.ebay.com/itm/321988738260 and this

http://www.ebay.com/itm/331367254243 this one seems to be the most comprehensive

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6 Riders · Post by **6 Riders** » 06:18 pm May 28 2016

That 3rs one has every gasket and seal, the second one is just oil seals and the first one is just gaskets. Since you have the whole motor apart, get the third one, I also recommend getting the second one as well, for extras.

Dekon · Post by **Dekon** » 09:26 pm May 28 2016

For the stator, you can rewind it yourself.

http://www.kdxrider.net/forums/viewtopi ... nd#p166729

Scroll down on this link and there is a stator rewind
http://www.kdxrider.net/forums/viewtopi ... =77&t=7198

ubareddition · Post by **ubareddition** » 10:08 pm May 28 2016

I saw that thread when i was browsing earlier. When i get everything pulled apart ill tackle that.

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ubareddition · Post by **ubareddition** » 10:10 pm May 28 2016

Just wondering if the bottom of that piston looks broken to you guys or if its supposed to look like that.

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6 Riders · Post by **6 Riders** » 10:13 pm May 28 2016

ubareddition wrote: Just wondering if the bottom of that piston looks broken to you guys or if its supposed to look like that.

Oh, that is broken. Good thing you are taking the bottom end apart, I'm sure that's where you will find the rest of it.

ubareddition · Post by **ubareddition** » 10:19 pm May 28 2016

So i need to find the rest of that huh? The easter egg hunt begins. Just curious is the crank only lubricated by the gas or does it share oil with the transmission?

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6 Riders · Post by **6 Riders** » 10:24 pm May 28 2016

ubareddition wrote:So i need to find the rest of that huh? The easter egg hunt begins. Just curious is the crank only lubricated by the gas or does it share oil with the transmission?

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Bottom end (crank) is lubed by premix, transmission is it's own entity. So no, they do not share oil.

6 Riders · Post by **6 Riders** » 10:25 pm May 28 2016

Oh, and spend a couple bucks donating to this site, that way you can PM me about my tail light.

ubareddition · Post by **ubareddition** » 10:26 pm May 28 2016

Im wondering what kind of dammage that peice of the piston did down there.

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