1991 KDX 200 Rebuild

Dekon · Post by **Dekon** » 06:21 pm Oct 30 2016

Looks really nice. I think the E-Series is one of the nicest looking bikes out there. But then again I might be biased as I have an '89.

Post by **KDXGarage** » 07:30 am Oct 31 2016

Wow. It looks completely different. Congratulations on a job well done.

hitmanhite · Post by **hitmanhite** » 10:08 pm Oct 31 2016

Awesome rebuild man. I can't believe Millenium missed that crack. That is their business to catch the little things like that. I was really hopeing you would get that crusty carb to work. I'm going to try to tackle that rear master cylinder as my first project on the 91 I just bought my son, thanks.

Post by **Tyl3r** » 10:59 am Nov 01 2016

Looks awesome! Great job man

TheGriz · Post by **TheGriz** » 09:49 pm Nov 05 2016

A quick update:

I found what I thought was a new "Keihin PWK 36" on ebay for $170:

No sizes engraved on the jets or slide, serial number number engraved in the side, no printing on the vent hoses, and no colored QC marks on the carb. It is amazing what detail the counterfeiters have included... what a shame.

When I cracked it open, i found that the jets were not labeled. Thinking that was strange, I called Sudco, the US importer, and found that this was counterfeit. I returned the carb after some minor hassle. I also found that the carb in the e-series is actually a PWK 35mm. It has a different size inlet and slide. I received it today and it runs great!

harry · Post by **harry** » 10:47 pm Mar 01 2017

heyyy, you did a great job here!! really help me in my bike rebuild for refference!!

any chance you have proper manual or partlist that you wanna shar with?

MaverickAus · Post by **MaverickAus** » 03:26 am Mar 02 2017

Nice job I'll reference this thread rebuilding my H.

TheGriz · Post by **TheGriz** » 10:42 pm Mar 04 2017

Thanks guys, for a manual, I just used: http://www.cyclepedia.com

Good news and bad news...

I modified a trail tech kick stand to fit the bike:

My good friend sold his 92' KDX and purchased mine... it hadn't even seen the trail yet. Couldn't pass up the offer.

I suppose that I'm now on the hunt for another project... :)

Post by **KDXGarage** » 06:04 am Mar 05 2017

LOL. Good luck with it.

TheGriz · Post by **TheGriz** » 03:56 pm Mar 10 2017

Thanks! Every time I sell a KDX, I have remorse and start the hunt for another! I think that I have as much fun rebuilding them as I do riding.

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