KDXRIDER.NET

Posted: **07:32 am Feb 19 2013**

Hi Guys,

I just want to find out if anyone has info on the rear suspension for the older models kdx 200?
I'm looking for anything to do with what oil i can fill it up with and what spring i must get for my weight (105 kgs)?
I have stopped looking for somewhere to help me rebuild or sort it out. because i got like a 1988 kdx 200 they all think its a lost cause.
The rear suspension is really soft and looks like it could have leaked some oil over all the years.
So i was thinking about getting a new spring made, because mine is pap and old, also maybe changing the oil that's in the shock because it looks almost black.. hahahaha

Any advice that people can help me with will be appreciated. Even if it is just how much oil to fill the shock up with will be great?
BTW i have never done this before so any info will help.

Thanks

Posted: **05:05 pm Feb 19 2013**

From another thread here (http://kdxrider.net/forums/viewtopic.php?f=77&t=13487:

Nah, if the bladder is still good, the real issue is getting all the air out... so you want to make sure the reservoir is full of bubble-free oil. Pull the line off, drain out the old oil , fill with new oil, connection port up, give it time for any bubbles to surface (gently tap the body with a plastic hammer) then connect the line, then fill it with oil - same process.
Connect the shock body up... then put about 35 lbs of air in the reservoir...this will help purge out any residual air bubbles in the reservoir.

Add oil into the shock body until it's about 3/4 inch from the top, put the shock shaft in SLOWLY, push the shaft up and down several times slowly making sure you don't come up too high and draw in air.... it should feel smooth after several cycles - with no "skips" from air pockets.

Now, with the shaft in it's fully extended (but still sealed) position, release the air in the reservoir.. you should feel the shock shaft go in slightly and be able to expose the circlip recess. Install the circlip (make sure it is seated).

Fill the reservoir with about 90 lbs of compressed air - and test the action of the shock, it should be smooth both ways and return to full length on its own.

Bleed out the air and fill with nitrogen - I'd recommend about 140 psi for this older unit.

RaceTech still has parts (http://racetech.com/ProductSearch/1/Kaw ... DX200/1988) as well, though they are stateside.

Posted: **06:45 pm Feb 19 2013**

Mines real soft to AA,pretty sure there's no nitrogen charge left and the oil's DOA.The thread bufftester quoted has more info as well http://kdxrider.net/forums/viewtopic.php?f=77&t=13487 the Clymer manual has a pretty good description of how to redo the shock.Shot me an email at snooksdad@gmail.com and I might be able to get you a scan.

Posted: **03:23 am Feb 20 2013**

Awesome thanks. I will go buy some oil and see how it goes.
Thanks for all the Help. GKBO i have dropped you a mail.

Posted: **06:46 pm Feb 22 2013**

I got that scan off to you.Finally figured it out.

Posted: **07:48 am Feb 24 2013**

Thank you, i has helped a lot.
i got some nasty black oil coming out.. hahaha, don’t think it has been cleaned in a while.

Posted: **08:28 am Feb 24 2013**

Hi guys,

I got another question.. When looking at the manual it says that there is only one O-ring in the shock.
It looks like the O-ring goes at the top to stop it from leaking, but it also looks like there could be one at the bottom, but i don’t know.
Would anyone be able to shed a bit of light on the matter for me?
This image is the full shock and you can see the O-ring at the top.

This one is of the bottom of the shock, but it looks like a o-ring can also go in there.

Thanks

Posted: **10:59 am Feb 25 2013**

What country are you from?? Your location is not shown.

That is not a 1988 USA KDX200 shock.

It looks like it is missing a bushing.

Posted: **11:00 am Feb 25 2013**

well, piston band and o-ring at least

Posted: **12:05 pm Feb 25 2013**

Hi,

Im from south africa.

GKBO scanned in part of the manual for me with the shock and this is what it should look like.

What you guys think?

Posted: **05:43 pm Feb 25 2013**

Are you saying yours looks like that? In the USA, the shock has the standard seal head cover that pops out, not the screw in kind. Can you post some pictures of the whole bike and whole shock?

It sounds a lot like you have the year wrong or someone installed a different shock or something.

EDIT: stolen from someone on TT... here is a picture of a USA 1986 - 1988 KDX200 shock.

Posted: **12:23 am Feb 26 2013**

hi,

mine has the screw and not the one that pops out.

here is a full pic of the shock.

Posted: **11:08 am Feb 26 2013**

Thank you very much for the picture. That makes me think it is a 1983 - 1985 shock.

Can you post a picture of the bike? Thanks.

Posted: **02:47 pm Feb 26 2013**

Hey Jason,

Here is where i started cleaning and rebuilding the bike.

http://kdxrider.net/forums/viewtopic.php?f=119&t=13271

Hope that helps. Thanks for the input also. I am happy for all the help that i can get

Posted: **05:21 pm Feb 26 2013**

OK, thanks. That helps a lot. From looking at the bike, I see several things that are not what would be on it in stock form on a USA model 1988 KDX200. The shock is from some other bike, not a 1988 model.

You may want to post the engine number, as it has a few things that don't look like what I am used to seeing on a USA 1988 model. In the USA, 1988 means Keihin PWK35 carb, silver crankcase halves, silver clutch cover, silver cylinder, silver head, silver KIPS covers, gray ignition cover, etc.

Some things may be correct for a South African 1988 KDX200, but I doubt it.

If you were in the USA, I would say 1986 or 1987 engine with a 1988 cylinder and pipe. The two springs on top of the pipe are a 1988 only feature in the USA.

Posted: **05:54 am Feb 27 2013**

Hey man,

Thanks for the quick reply.
The number on the bottom of the engine is (and it looks like) KHI DX200 - CE 003921
i don't know if that does mean anything to you?

Posted: **09:33 pm Feb 27 2013**

Off the top of my head, that is 1986 or 1987. It is (to me), borderline of either one. I do have the '85-87 Kawasaki Model Identification Guide, but it is lost in clutter right now. I can not remember if it specifies when one year starts and another ends or not on the KDX's of that era.

In the USA, 1986 models came with a steel braided front brake hose, then went to rubber for 1987 and 1988.

Do you have a frame number or a VIN? I have read posts from European models and UK models having frame numbers.

Posted: **09:39 pm Feb 27 2013**

I like the blue frame in your other thread. Mine used to be blue, also (years ago).

Posted: **09:42 pm Feb 27 2013**

Sorry to be off topic again, but do you think that cylinder was replated at some point? I know stock 1988 pipe had two springs on top instead of just one like 1986 and 1987, but can not remember if it was two different mounting holes.

Thanks and good luck on the bike. I like those year models.

KDXRIDER.NET

Rear suspension

Rear suspension

Re: Rear suspension

Rear suspension

Re: Rear suspension

Re: Rear suspension

Re: Rear suspension

Re: Rear suspension

Rear suspension

Re: Rear suspension

Re: Rear suspension

Rear suspension

Re: Rear suspension

Rear suspension

Re: Rear suspension

Rear suspension

Re: Rear suspension

Re: Rear suspension

Re: Rear suspension

Re: Rear suspension