A few questions about my 94 kdx200

Dekon · Post by **Dekon** » 07:40 am Oct 07 2016

When I first got mine the oil plug was stripped. I put a helicoil in as a temporary fix. When I split the cases I drilled and tapped it.

As for the clutch, did you soak the plates in oil before installing them? They will swell a little when they get oil on them.

ubareddition · Post by **ubareddition** » 07:50 am Oct 07 2016

Yeah I soaked them

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Dekon · Post by **Dekon** » 09:20 pm Oct 07 2016

I had this happen once, the washer came off the back of the basket and wedged between the basket and the hub when I was installing it.

ubareddition · Post by **ubareddition** » 05:24 pm Oct 10 2016

My gas tank also has a small crack in it that needs to be addressed until I can order a aftermarket larger one. I walked in the garage for a tool and it just stank of gas. There was a pretty good pool around where I set my tank. The crack is maybe 3/4 of an inch long. On the right hand upper part of the tank. I forgot to take pics.

Dekon do you happen to know the size of those threads so I can order the helicoil for it.

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Dekon · Post by **Dekon** » 12:47 pm Oct 11 2016

Sorry don't remember the exact size, I think the drain plug is 10mm X 1.5, but don't quote me on that.

I know the size if you drill and tap the case, it's 7/16-20 tap and a 25/64 drill. Get yourself a 7/16-20 bolt and you're good to go.

black · Post by **black** » 09:28 am Oct 12 2016

I asked on this board if there was gas tabk larger than stock for the '94
Seemed there was non other than just retrofitting some other bikes tanks to fit like a KX ?

ubareddition · Post by **ubareddition** » 10:38 am Oct 12 2016

No there is one. I can't remember the name of it.

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ubareddition · Post by **ubareddition** » 11:01 am Oct 12 2016

Clarke I think makes it.

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ubareddition · Post by **ubareddition** » 11:14 am Oct 12 2016

Oh I got the bike to go into nuetral.
I was cleaning up in the garage last night. Labeling the bolts and parts I took off this time. I took it off the stand to sweep the floor under it. Was pushing on the handle bars while pushing and pulling on the shifter on the shifter and it finally shifted up twice then stopped so I assumed that was 6th. Pushed it down 4 times then a half push and I could push it around the garage. Now I just gotta figure out the clutch situation.

And fix this

Still waiting for word back from the machine shop.

But I heard back from south dakota. Hopefully my plates will be back soon. Even though I can't ride till I get this piston and cylinder issue fixed. At least that gives me time to fix everything else.

Also gotta fab up a better kick stand. a plate holder With a light.

tighten that kick starter spring.

Helicoil or retap that drain plug.

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Davenay67 · Post by **Davenay67** » 11:32 am Oct 12 2016

Any progress is good. Keep the momentum going.

I've read in depth about the South Dakota plate method. Did you have title or use a bill of sale for your plates. Are you going to transfer SD plates to your own state plates?

ubareddition · Post by **ubareddition** » 01:14 pm Oct 12 2016

I had no title. The state of ri does not issue titles to vehicles older than 2001. So I made an affidavit statement to that effect. There's a thread detailing it somewhere here.

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david · Post by **david** » 01:32 pm Oct 12 2016

Clarke doesn't specify the 89-94 KDX, but they do make a stock and oversized for the KX500, which looks the same but I'm not sure if it fits.

Here is a stock one at half the price of a Clarke
http://www.ebay.com/itm/1990-Kawasaki-K ... g7&vxp=mtr

And your side stand.
http://www.ebay.com/itm/KAWASAKI-KDX200 ... US&vxp=mtr

Post by **KDXGarage** » 02:37 pm Oct 12 2016

Are you interested in buying a used tank, or just a larger one?

ubareddition · Post by **ubareddition** » 03:02 pm Oct 12 2016

I'm intrested in a larger tank. I think I'm just going to patch this one and save for a larger upgraded tank.

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ubareddition · Post by **ubareddition** » 03:05 pm Oct 12 2016

That side stand says it's out of stock.

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Post by **KDXGarage** » 03:05 pm Oct 12 2016

OK, thanks.

david · Post by **david** » 12:52 pm Oct 13 2016

ubareddition wrote:That side stand says it's out of stock.

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Then they sold it. Keep looking, a good used one may pop up.

ubareddition · Post by **ubareddition** » 08:50 pm Oct 13 2016

So the machine shop wasn't much help. He basically confirmed that the cylinder was really out of wack but said he didn't want to get involved as far as giving me a written evaluation. I also think he was kinda out of his element. I don't think he's ever done anything with a 2 stroke or a bike. He's more of a car machine shop. So I'm wondering if I should try to find a bike specialty shop or if I should just roll the dice and ship out the cylinder.

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pumpguy · Post by **pumpguy** » 11:17 am Oct 14 2016

I would get something in writing from someone with a degree of expertise in this area. If they say it's bad workmanship, it might be worth a few bucks to pay them for their written opinion.

Without that, you have no ammo to contest the judgement call of the original plater, and you're totally at their mercy.

On the other hand, if they say it's customer abuse, or can't say one way or the other, well, there's nothing left to do but send it back to the original plater and trust to their judgement and fairness.

KDXohio · Post by **KDXohio** » 11:51 am Oct 14 2016

I hope you have better luck than I have in the past I had a cylinder bored for an xr200 that ended up with excessive clearance which led to excessive ring Gap. Put the whole thing together trusting the Machine Shop and it had less compression and poured more smoke then before the rebuild. I pulled everything back apart and took it back in still looking brand new perfect cross hatching no marks on the piston and they basically said I must have used the wrong oil or did an improper break in procedure there is no amount of arguing I could do to get them to fix their mistake. However I was able to dispute the charge with my credit card company and get my money back for the machine work.

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