An ambitious 86 200 project

Roadhazardguy · Post by **Roadhazardguy** » 11:54 am Jan 09 2013

You just start by applying light pressure and you can increase pressure as you get comfortable with it. You could also try using a heat gun on it, it melts the outside layer of old plastic back to a nice bright color.

rbates9 · Post by **rbates9** » 06:46 pm Jan 09 2013

Somewhere on here there is a link to a site that they showed how to do it. I cant remember the name of the topic but you could probably find it with a search.

Roadhazardguy · Post by **Roadhazardguy** » 08:26 pm Jan 09 2013

Yeah there are writeups on the web that show how to do it. I may have made is sound like a delicate process but its really not, as long as you don't run the blade length wise and put a big gouge in it there's really not much you can screw up. Its mainly just time consuming, go for it.

GKBO · Post by **GKBO** » 02:48 pm Jan 12 2013

One step closer http://kdxrider.net/forums/viewtopic.php?f=77&t=13338

GKBO · Post by **GKBO** » 07:33 pm Jan 13 2013

It's strip her down day,well mostly.

How do you get this piece off?Looks to me like the pivot unbolts but it's been ground down.Anyone confirm that?The cotter pins are rusted into the peg pins.Get to those another day along with the suspension mounts still on the frame.

Seems my local shop has done some work on this bike in the past,cool!

Swingarm and all the other rear suspension pivots are in great shape I'm VERY happy to report.
Cont.

GKBO · Post by **GKBO** » 07:55 pm Jan 13 2013

Shoes and drum look OK to.

So I cleaned up some bits on the wire wheel.
Overall it went pretty easy as I've been soaking the bolts in penetrating oil since I got her home.Front and rear wheel bearings will need to be replaced but all thing considered It could be WAY worse.I was expecting it to be a real pile looking at it so I'm pretty happy.Guessing this was someone's pride and joy not that long ago.

GKBO · Post by **GKBO** » 08:13 pm Jan 13 2013

Hey what is the stock 86 stanchion size? Through it was 38mm but the ones I have here are 43,that right for an 86?

Goofaroo · Post by **Goofaroo** » 09:40 pm Jan 13 2013

Hey what is the stock 86 stanchion size? Through it was 38mm but the ones I have here are 43,that right for an 86?

Yep. They are correct.

GKBO · Post by **GKBO** » 05:08 am Jan 14 2013

Nice,was looking at them and saying to myself "those look WAY bigger than the 37's on my 85 GS750".
Can I get an answer to this question?
How do you get this piece off?Looks to me like the pivot unbolts but it's been ground down.Anyone confirm that?

Post by **dfeckel** » 11:03 am Jan 15 2013

Those rear brake parts cleaned up nice!

I can confirm that the brake pedal pivot unscrews. Here's a pic of my '87.

I used a hex head bolt because I trashed the phillips head screw that was originally holding it in. Here's a pic of my '83 KDX 250 that shows the screws.

I'm thinking PB Blaster with a chisel would probably get your ground-down screw out.

GKBO · Post by **GKBO** » 05:38 pm Jan 15 2013

Thanks David,That's what I thought but getting a confirmation really helps.The whole project took a big step forward,the go between member received the airbox today.Emailed me to tell me it looks good with all the bits including a decent filter :boogie:Out to hit it with the penetrating oil.

GKBO · Post by **GKBO** » 09:32 pm Jan 19 2013

Got the frame all stripped down,got the brake pivot screw out by slotting it with the dreamer then using the impact driver on it.Going to get a bag of ground walnut shells to blast it with.Going to try blue farm and implement paint on the frame.Think that will look good with the gaiters and seat.

Roadhazardguy · Post by **Roadhazardguy** » 11:53 pm Jan 19 2013

Hey watch this video:
[youtube][/youtube]
Skip to the 3 minute mark.

Some good tips in there, I've been adding hardener to Rustoleum for a while now and it makes the paint much nicer and tougher. I haven't tried that reducer yet but I plan to next time I paint something, Ive just been using acetone.

GKBO · Post by **GKBO** » 05:56 am Jan 20 2013

Hmmmmmmm..............Wonder if that's the same as the One-shot hardener I found when I was trying my hand at pinstriping.Not patient or steady enough to do that by hand :sad:I found a vid on what you where talking about with the razor blade RHG.It isn't as hard as I thought it could be.Think I'll give that a try.Use the buffer to finish though,just because

Roadhazardguy · Post by **Roadhazardguy** » 01:29 pm Jan 20 2013

Definitely use the buffer, that's what made it come out really nice!

GKBO · Post by **GKBO** » 10:25 pm Jan 21 2013

Needed to get something done on the KDX so I decided to clean up the tank,this is the before.

After using a box cutter blade to scrape off all the oxidised plastic.

Then I sanded,first with a sponge.Then with 400 wet & dry,finishing with 1000.

Off to the buffer.Will admit I over did it and had a bit to clean up.Got to have a light touch polishing plastics.Think I'm still getting used to the new 8" buffer as well.Was using a 6" grinder before.The new one's got more oomph.Not perfect but she's an old dirt bike,deserves keep some "battle scars"

Thedude1973 · Post by **Thedude1973** » 10:39 pm Jan 21 2013

Impressive work on that tank!

Roadhazardguy · Post by **Roadhazardguy** » 12:03 am Jan 22 2013

Looks good!

GKBO · Post by **GKBO** » 05:28 am Jan 22 2013

Forgot this one,PO's

GKBO · Post by **GKBO** » 05:46 pm Jan 23 2013

Got the walnut shells and paint for the frame,now all I need is a few nice days.Could be a while here on the wet coast

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