1991 KDX 200 Rebuild

ubareddition · Post by **ubareddition** » 10:23 am Oct 04 2016

I used a small polishing wheel on my dremmel to do mine.

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david · Post by **david** » 11:58 am Oct 04 2016

Try some oven cleaner.

ubareddition · Post by **ubareddition** » 12:15 pm Oct 04 2016

No no no. Unless you immediately wipe it off. The lye eats the metal.

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Post by **KDXGarage** » 12:24 pm Oct 04 2016

Try not to put oven cleaner on aluminum.

david · Post by **david** » 12:25 pm Oct 04 2016

ok, mental note, no oven cleaner on aluminum.

TheGriz · Post by **TheGriz** » 01:33 pm Oct 04 2016

I've heard using Shout might work as well.

Post by **KDXGarage** » 01:46 pm Oct 04 2016

No. Shouting and cursing don't get the job done. Wait. Nevermind.

TheGriz · Post by **TheGriz** » 06:29 pm Oct 06 2016

There were very slight grooves int he clutch basket fingers. I decided to do some light filing on them rather than replace the basket. Buying a new basket would be a budget killer!

New intake manifold and gasket. Reeds were usable... I think.

Apparently the 1991 model has two water pump seals. When looking at exploded diagrams, I learned this and just received the second seal today:

The water pump impeller was blasted and painted with high temp. It looks bad, but should work well.

I figured out where that extra washer belonged!! This was bothering me and am glad to have found a home for it:

I put the clutch together in reverse of how I disassembled it... no pics of that process. Water pump covers and new gaskets as well as a nicely cleaned up clutch cover:

I cleaned the engine cases with degreaser and a stiff bristled brush: I didn't have the patience to do any better than this:

ubareddition · Post by **ubareddition** » 06:40 pm Oct 06 2016

Dang I was really hoping you would get some pics of how that clutch went together. I'm having issues with mine.

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TheGriz · Post by **TheGriz** » 07:06 pm Oct 06 2016

Really? I just reversed the procedure for disassembly. What specifically are you having trouble with?

ubareddition · Post by **ubareddition** » 08:29 am Oct 07 2016

My clutch won't disengage.

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TheGriz · Post by **TheGriz** » 11:49 am Oct 07 2016

Have you looked at the clutch basket fingers? Old baskets get little horizontal grooves worn into the from hours of wear and tear. This was the filing that I did. I had an old KX125 that wouldn't disengage due to this.

I assume your cable is pulling through smoothly?

TheGriz · Post by **TheGriz** » 11:52 am Oct 07 2016

Not my picture, but this is an example of a filed finger vs a worn finger.

TheGriz · Post by **TheGriz** » 11:59 am Oct 07 2016

Left for a week of work on my cabin in Northern Michigan, so no updates for a week.

I've been enjoying this rebuild...

After packing up the truck, I couldn't resist setting the engine back in.

ubareddition · Post by **ubareddition** » 12:01 pm Oct 07 2016

I filed my clutch basket.

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two-stroke-brit · Post by **two-stroke-brit** » 03:54 pm Oct 09 2016

great thread read it from start to finish.
cheers mark

KDXohio · Post by **KDXohio** » 05:22 pm Oct 09 2016

Looking great!

TheGriz · Post by **TheGriz** » 08:06 pm Oct 17 2016

Back from Michigan and trying to find time to finish up the KDX.

Carb and rear shock back in:

New Radiators look fantastic:

Post by **KDXGarage** » 10:25 pm Oct 17 2016

Coming together!

TheGriz · Post by **TheGriz** » 06:43 pm Oct 19 2016

Waiting for rubber bushings for the silencer:

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