My Air Cooled KDX 200 1989 Rebuild

ArkAngel · Post by **ArkAngel** » 02:52 pm Dec 20 2012

Hi Guys,

I thought i would share with you my Rebuild of a second hand bike that i bought.
I have been on the site since i got my KDX and what a awesome bike it is.
I love the vids and pics that everyone posts and its all quite adictive. hahaha

It has been really fun riding it but now i think its time to clean it up and make it AWESOME again.
The Bike was sold to me as a KDX 200 1990 model, but as Ive been doing some research i discovered that the last was made it 1989, so i thought that's what i might have bought.
So this is how i bought the bike a few months ago.

sorry for all the pics and the size of them.
This is the bike how it stands now.

Now i started pulling it apart.

If you guys have any input or suggestions, please feel free to comment and help with anything.
This is my fist bike that i have ever owned and rebuild. But i have built my own 2 Door Golf GT before.
I do have something to ask anyone that might know, i need the dimensions of a bike stand that i can build for the bike to stand on during the rebuild?

Tomorrow i want to remove the wheels, exhaust and hopefully the engine.
Then i might ill be closer to respraying and cleaning everything.

Hope you guys will give me some input and info.

Thanks

sarrant · Post by **sarrant** » 03:51 pm Dec 20 2012

1989 KDXs are liquid cooled. It's an 86-88.

Post by **Julien D** » 07:37 am Dec 21 2012

Correct, 86-88, since it's power valved and air-cooled. Should make a fun bike! Seems their biggest downfall is in the flywheel, so it's a good idea to pull it and make sure the magnets are in good shape. Easier to epoxy a little now than source another flywheel later. Same piston for 86+ 200, so that piece is easy to find. Some parts will be ebay/craigslist only.

ArkAngel · Post by **ArkAngel** » 10:56 am Dec 21 2012

Thanks for the reply's guys.
I will check that later then Julien, anything else that you think i must check? i will post a few extra pics later.
I have found that i might need a new shock and chain guide, but ill post some pics and maybe the you guys / experts can give me some advise on the parts.
Just want to clean a few of the parts now before a take pics. The previous owner loved and when i mean LOVED his grease he got it and put it everywhere.. lol

kawagumby · Post by **kawagumby** » 12:03 pm Dec 21 2012

That's likely an 86 or 87 based on the Mikuni carb. Be careful when you pull the flywheel, use the correct puller. There's a lot of evidence that the reason the magnets come loose is stress to the housing (breaking the expoxy bonds) from people trying to pry the flywheel off.

Slick_Nick · Post by **Slick_Nick** » 01:07 pm Dec 21 2012

They don't build 'em like the used to, huh?

sarrant · Post by **sarrant** » 01:55 pm Dec 21 2012

They don't build 'em like the used to, huh?

They really don't.

I've been looking for something similar to a C Series KDX for my gal for a long time. There is very little currently in production remotely comparable when it comes to performance/seat height/weight. She feels the 125/150 four strokes are like kids' toys, and everything else is too big/heavy for a smaller rider.

Post by **SS109** » 07:20 pm Dec 21 2012

sarrant wrote:
They don't build 'em like the used to, huh?
They really don't.

I've been looking for something similar to a C Series KDX for my gal for a long time. There is very little currently in production remotely comparable when it comes to performance/seat height/weight. She feels the 125/150 four strokes are like kids' toys, and everything else is too big/heavy for a smaller rider.

Too bad you aren't close as I see C series bikes up for sale quite often here in AZ. There was even a sweet '88 white model for sale a while back.

sarrant · Post by **sarrant** » 08:13 pm Dec 21 2012

SS109 wrote:Too bad you aren't close as I see C series bikes up for sale quite often here in AZ. There was even a sweet '88 white model for sale a while back.

She had been riding a 90s Yamaha RT180 for the last decade. We we're looking for newer options to replace it, and she was just underwhelmed by all the smaller 4-strokes and (at 5'3, 130) overwhelmed by full size bikes. So, I had my eye out for something similar to a C-bike. There's just not many good ones out there.

And then, on Thanksgiving, the trusty, crusty old RT180 got ripped off while we we're visiting the family. Grrr.

So I just bought her a KX125 for Xmas, and I'm process of shimming down the suspension, and will be adding flywheel weight and getting the cylinder base milled to tame it a bit. If she likes the handling/feel of the shorty KX, long term goal is a hybrid project. I've got about 90% of an E series motor sitting on the shelf.

ArkAngel · Post by **ArkAngel** » 04:37 am Dec 25 2012

Hey Guys,

Merry Xmas to all.
I just want to find out something, what size sprocket do you guys use for trail riding? back (tire) and front (engine)? 48 back and 8 front? I hope someone understands my Noob ways (lol the thing my chain runs on).
Someone told me their is a difference in trail and mx or something like that.

sarrant · Post by **sarrant** » 12:35 pm Dec 27 2012

KDXs come pretty well geared for trail riding. 48 tooth is stock gearing in back. The front (countershaft) should be a 13 stock. I don't think there's even such a thing as an 8 tooth countershaft sprocket.

ArkAngel · Post by **ArkAngel** » 03:24 am Dec 28 2012

yes sorry my mistake. its 13 in front.

ArkAngel · Post by **ArkAngel** » 03:51 pm Dec 28 2012

Just thought i would show some before and after shots of the frame :D

and after..

Ill post some more Images tomorrow.

Post by **KDXGarage** » 08:20 pm Dec 28 2012

black engine and non-braided brake hose = 1987

Keep up the good work.

ArkAngel · Post by **ArkAngel** » 10:43 am Dec 29 2012

What i have done is spray the engine black and light sanding of the fins to make it really shine in the sun. I have seen something like this done on other KDX air cooled bikes and it looks really great.
So this is how it looks at the moment...

Let me know what you guys think?

GKBO · Post by **GKBO** » 11:27 am Dec 29 2012

What did you use to paint the frame,PC? PC is way out of my budget here in The Great White North.

ArkAngel · Post by **ArkAngel** » 11:46 am Dec 29 2012

GKBO wrote:What did you use to paint the frame,PC? PC is way out of my budget here in The Great White North.

I used 2k motor / metal paint. Its kinda expensive but well worth the outcome and it does not scratch or chip that easy.
I am just glade that the blue came out like it did, because i never used that color blue paint before.

Roadhazardguy · Post by **Roadhazardguy** » 01:02 pm Jan 09 2013

Nice bike, I like what you did with the engine! It looks like a 86-87 probably a 87 though.

GKBO · Post by **GKBO** » 05:00 am Jan 10 2013

ArkAngel wrote: I used 2k motor / metal paint. Its kinda expensive but well worth the outcome and it does not scratch or chip that easy.
I am just glade that the blue came out like it did, because i never used that color blue paint before.

Nice,still pondering the colour I want to do my frame.I used appliance "epoxy" (really just a strong enamel) on my street bike frames and it's worked well.Problem is limited colour choice.

ArkAngel · Post by **ArkAngel** » 06:49 am Jan 16 2013

GKBO wrote:
ArkAngel wrote: I used 2k motor / metal paint. Its kinda expensive but well worth the outcome and it does not scratch or chip that easy.
I am just glade that the blue came out like it did, because i never used that color blue paint before.
Nice,still pondering the colour I want to do my frame.I used appliance "epoxy" (really just a strong enamel) on my street bike frames and it's worked well.Problem is limited colour choice.

That is also true.

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