1986 KDX 200 rebuild

hbgod · Post by **hbgod** » 08:15 pm Jan 07 2014

Dekon wrote:Looking good. You might want to remount the front brake hose. The hose should go between the fork leg and wheel after the bottom hose clamp. It's a little unprotected out there like that.

Well the goal is more or less a street-legal air-cooled 2-stroke supermoto so im not to worried about that but i do see your point. plus the whole front end is off an 86kx 125 not the kdx.

hbgod · Post by **hbgod** » 04:29 pm Feb 01 2014

So got the cylinder sleeved and ported. now im going to clean the bottom end, check the clutch, and rewire the stator. then sending off the bottom end for crank bearings, rod bearing, and connecting rod. then shes getting dyno tuned :)

hbgod · Post by **hbgod** » 06:06 pm Mar 31 2014

so finally got the kickstarter off the engine. with alot of heat and prying, split the cases, and did a bunch of other stuff. looks like this engine has VERY low hours and just sat most of its life.

ready to be split for new rod and bearing

one main bearing was frozen on the crank. vice broke the outer casing and we grinded off the inner piece

box of parts to be cleaned

had a warm day so i cleaned the garage

and my new main bearings arrived :)

Dekon · Post by **Dekon** » 07:57 pm Mar 31 2014

Great to see your still plugging along on this. Looks like the end is in sight.

hbgod · Post by **hbgod** » 08:04 pm Mar 31 2014

Dekon wrote:Great to see your still plugging along on this. Looks like the end is in sight.

working on it. engines just about finished so once thats done ill be in a rush to finish the rest of the bike :)

hbgod · Post by **hbgod** » 08:17 pm Jun 02 2014

Got the shock looking all pretty.

i didnt end up replacing the head seal bc there was so much crap under the cap and i couldnt even see the circlip. but considering it still had fluid and nitrogen inside of it i think itll be all good.

I am having an issue with the carb though. its not the original carb and i dont have the plastic screw on top. so not sure if im gonna source a cap or just get another carb. motor itself is almost done though so thats a plus :)

Dekon · Post by **Dekon** » 08:30 pm Jun 02 2014

Wow, the shock looks brand new!

hbgod · Post by **hbgod** » 09:43 pm Jun 02 2014

Dekon wrote:Wow, the shock looks brand new!

thanks man, i do good finish work. little bit of sandpaper(dremel for hard to get places), carb cleaner, and paint. :)

hbgod · Post by **hbgod** » 02:03 pm Jun 09 2014

Im having an issue with this carb. im pretty sure its from an 88. its a keihin. but i dont have the cap to it and cant seem to source one.

hbgod · Post by **hbgod** » 08:11 am Jul 14 2014

So quick update. Got a 36mm PE Keihin Carb off ebay and im using a 95 kx125 intake manifold. It fits and is going off along with the rest of my engine to get dyno tuned. OOOOOOOO SOOOO CLOSE I CAN HEAR HER SCREAMING. also gave my stepdad some cash and info on the bike and hes gonna try and get me a street title in maine since they dont require any paperwork to register stuff. Lets hope all goes well. if so ill have a running motor and a titled frame.

hbgod · Post by **hbgod** » 09:31 pm Aug 09 2014

Looking good ;)

Lazy way to paint your master

Hammered Bronze levers ;)

This stuff is pretty cool. got my killswitch and clutch cable covered with it.

Dekon · Post by **Dekon** » 08:31 pm Aug 10 2014

Nice!

hbgod · Post by **hbgod** » 07:26 pm Aug 24 2014

So decided to scrap the PE36 idea and bought a PWK35 off a newer KDX along with the intake boot. Also going to to call Vermont DMV tomorrow and see about getting an out of state plate. Replaced the rear wheel bearing and got the rear tire on the bike as well.

hbgod · Post by **hbgod** » 09:13 am Aug 27 2014

So Got a nice update for everyone today. Ill start out with the fact that i sent out the rest of my motor and everything to actually run the bike on an engine dyno today so i will have a running bike sometime in the near future (fingers crossed).
and the second part of this update is i just talked to the Vermont DMV and the conversation went something like this

Me: Hi id like to register my 86 KDX200 what NADA Value do I use for the sales tax?
DMV: We do not register dirtbikes. The vehicle would have to be able to pass safety inspection.
Me: It will be able to pass safety inspection before it ever leaves my driveway(listed all parts)
DMV: OK, the Sales tax goes by the rough trade in value $39.30 + $44 registration fee and also send us the bill of sale and registration form.

WOOHOO Street title here i come ;)

So after 2 long years and end is in sight. Once the engine is finished and i get my paperwork in the mail the rest is just coming up with some money to get the other odds and ends to finish the bike.

DOT tires
blinkers
headlight/tailight
horn
New Plastics
Throttle cable
rear brake rod
battery, rectifier, and 12v converter. (86 kdx is 6v? or at least the headlight is)
chain and sprockets
handlebar controls for horn and blinkers
recharge the shock
and going to make a skidplate once i have the motor mounted in the bike.

I think thats all i still need to finish the bike. :) it will deffinetly be finished come spring time.

Post by **KDXGarage** » 11:11 am Aug 27 2014

Good work so far and good luck.

hbgod · Post by **hbgod** » 05:32 pm Aug 28 2014

Jason wrote:Good work so far and good luck.

Thank you! cant wait till she's done. money is really the only obstacle now.

hbgod · Post by **hbgod** » 11:14 am Sep 26 2014

Got my registration and plate in the mail today from vermont. time to order street parts ;)

hbgod · Post by **hbgod** » 07:02 pm Oct 04 2014

Some more pictures for you guys. Started restoring the tank but still a way to go, got a supermoto front fender on it right now but its alittle shorter than i thought it was gonna be. I like the newer style pointy fenders :) Waiting to get paid on the job i just finished and once i do gonna order a headlight and some other stuff hopefully gonna start wiring her up and get the motor back soon.

hbgod · Post by **hbgod** » 07:15 pm Oct 04 2014

Also made a rear brake rod out of 1/4 threaded rod and some springs. lets see how well itll work.

hbgod · Post by **hbgod** » 05:32 pm Oct 25 2014

Modified a 92 kx250 rear fender to fit and bought reproduction number plates from DC plastics

Got alittle further with the tank and mounted up my headlight

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