It begins! '90 KDX200 rebuild

Post by **KDXGarage** » 05:31 pm Apr 30 2012

Great work! Thanks for sharing the rebuild.

Post by **SS109** » 10:52 pm May 10 2012

Now both wheels are completely done! Hopefully will actually start putting the engine back together this weekend... maybe. Seems like something always comes up and gets in the way right now.

KDX200-E2 · Post by **KDX200-E2** » 12:24 am May 11 2012

Your bike is going to be TOO nice to ride! Better build a podium in your living room to display it.

Then get another bike to really ride.....

Love to see it when you are finished.
Jeff

Post by **SS109** » 02:51 am May 11 2012

I wish it would look that nice! I think it will be a solid 5 footer except for the fuel tank. I have tried everything to whiten it, and there were some very noticeable improvements, but there is still some discoloration in spots. Everything else should look pretty good though!

diymirage · Post by **diymirage** » 10:47 pm May 11 2012

SS109 wrote:I wish it would look that nice! I think it will be a solid 5 footer except for the fuel tank. I have tried everything to whiten it, and there were some very noticeable improvements, but there is still some discoloration in spots. Everything else should look pretty good though!

have you tried polishing it with whitening toothpaste?

Post by **SS109** » 12:55 am May 12 2012

diymirage wrote:
SS109 wrote:I wish it would look that nice! I think it will be a solid 5 footer except for the fuel tank. I have tried everything to whiten it, and there were some very noticeable improvements, but there is still some discoloration in spots. Everything else should look pretty good though!

have you tried polishing it with whitening toothpaste?

No, Haven't tried that!

However, I used a Magic Eraser pad and it cleaned up the tank pretty good but couldn't remove the serious stains. Next I tried a trick used in the restaurant biz to remove stains from HDPE buckets using bleach and sunlight. It removed almost all staining but one area just wouldn't clean up much. If I had a better tank to start with it probably would look like new again. I'll try to post up a pic of the tank later.

Post by **SS109** » 01:20 am May 14 2012

Oh, yeah, I almost forgot. I picked up a few more items for my build. I bought new Motion Pro clutch (Terminator) and throttle cables and new No-Toil air filters.

Frysk · Post by **Frysk** » 03:24 pm May 31 2012

How did you get your hub so clean

Post by **SS109** » 07:40 pm May 31 2012

Frysk wrote:How did you get your hub so clean

Soda blasting! Works awesome on cast aluminum parts.

rbates9 · Post by **rbates9** » 09:24 pm May 31 2012

SS109 wrote:
Frysk wrote:How did you get your hub so clean
Soda blasting! Works awesome on cast aluminum parts.

Frysk · Post by **Frysk** » 11:44 am Jun 02 2012

Hmm, to bad I don't know anybody with a sodablaster

Post by **SS109** » 11:53 am Jun 02 2012

Frysk wrote:Hmm, to bad I don't know anybody with a sodablaster

Funny as neither do I!

I cheated and used a spot sandblaster. I used this exact one: http://www.harborfreight.com/21-oz-hopp ... 95793.html, bought a 50lb bag of soda media from the same place, and ran it of my Craftsman 5.5hp 30g air compressor at 110psi. It was really messy but it worked well.

Post by **SS109** » 01:38 pm Jun 07 2012

OK, I got the trans shafts reassembled and ready to go. Just dropped my crank into the right side case and waiting for it to cool off. Next, install the trans!

BTW, to any who haven't tried the heat case/freeze crank method for installing the crank, it works like butter! I left my crank in the freezer overnight, then heated the right case half from a cold oven to 225 degrees for about an hour, and the parts slid together with absolutely zero resistance. I plan on doing the same for the left side as well.

rbates9 · Post by **rbates9** » 03:21 pm Jun 07 2012

I thought about heating and freezing for the left side as well but I was concerned about using the case sealer on a frozen surface then dropping a HOT surface on it. I don't know how the temperature difference would workout as far as having a good bond and seal.

Let us know

Post by **SS109** » 05:40 pm Jun 07 2012

I don't think it should be a problem. I guess I'll find out for sure before long! I'm kind of on hold until I get a new case bolt as one is bent. I won't get into how that happened but suffice it to say that it had to be the odd ball long one.

Oh, yeah, just got back from dropping my frame off to have it sand blasted. They are saying it is roughly a 10 day wait right now so time to work on other parts.

rbates9 · Post by **rbates9** » 07:57 pm Jun 07 2012

I know a guy that has a crank puller that works great for getting the cases back together.

Post by **SS109** » 08:20 pm Jun 07 2012

rbates9 wrote:I know a guy that has a crank puller that works great for getting the cases back together.

Well, it isn't me so who might it be? I would love to have a loaner!

rbates9 · Post by **rbates9** » 08:59 pm Jun 07 2012

PM me. I'm sure we can work something out.

Post by **SS109** » 06:31 am Jun 09 2012

I remembered today that I have a spare KDX trans so I started really looking at my gears and realized the 6th gear on the output shaft the dogs have very noticeable wear on them. So, I pulled the one from the spare trans and the dogs are in great shape! Unfortunately, there is some damage to two adjacent teeth so now I'm stuck trying to decide which one to use or if I should be looking for another one. What do you guys think?

Original gear is on the left and the spare on the right. You can see the dogs are worn pretty good. (click it for a bigger pic!)

OK, here is the damage on the spare gear's teeth circled in red.

david · Post by **david** » 12:27 pm Jun 09 2012

The 'damage' on the spare is nothing. Dress it with a file and run it.

KDXRIDER.NET

KDXRIDER.NET