1992 KDX200 project

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
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Goofaroo
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1992 KDX200 project

Post by Goofaroo » 10:03 am Dec 28 2020

I found this bike about 9 years ago for my son in law. I brought it home and freshened it up for him but he hardly ever rode it and it has pretty much just sat in my barn. I have always liked it so I finally decided to buy it from him and make it my own.

I had the shock rebuilt and revalved by my suspension guy back when we first bought it. I also went through the forks so the suspension is nicely sorted for now.

The engine had been gone through by a local shop before we bought it and is very solid. I have the carb off and all it needs is a new bowl gasket which is on the way.

The only real problem I have is that the tank is cracked at the bottom near the petcock so that needs to be addressed. I’ll be changing all the fluids and giving it a general going over but the majority of my mods will be cosmetic. I’m shooting for kind of a period correct European ISDE look if that makes any sense. lol

So far I have purchased the headlight. I’m not sure yet what else I will need but I may use some different handguards, front fender, etc.

To stay period correct I am going to stick with the blue seat, fork boots, and tool bag. Unfortunately the 92 seat has the pink splatter pattern. The cover is in great shape but the pink needs to go. Has anyone figured out a way to remove it. I’m all ears.

Here is my starting point. I have all of the plastic but have removed it to get going on this project.
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Re: 1992 KDX200 project

Post by Goofaroo » 12:05 pm Dec 28 2020

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Doing a bit of trial fitting of the headlight bucket. I chose it to give it a Euro appearance plus I have always loved the look of the Elba lights. I’m going to need to drill a hole and put a grommet in it to route the odometer cable through.

Anyway, it kind of shows the direction I’m trying to go with this build.

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Re: 1992 KDX200 project

Post by KDXGarage » 01:11 pm Dec 28 2020

WOW. I remember seeing those headlights in ads a LOOOOOONG time ago.

Good luck on the build.
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Re: 1992 KDX200 project

Post by Goofaroo » 07:08 pm Dec 28 2020

KDXGarage wrote:
01:11 pm Dec 28 2020
WOW. I remember seeing those headlights in ads a LOOOOOONG time ago.

Good luck on the build.
Yep. I hadn’t seen them around since back in the early 90s but a few months ago they started popping up on EBay. I ordered one and figured I would need to find a project bike for it. It just happened to work out that the bike was already in my barn. lol

It’s been a long time since I rode this KDX but I really enjoyed it. I’m planning to make it my primary woods bike and it doesn’t need that much work to get it up to spec.

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Re: 1992 KDX200 project

Post by Goofaroo » 03:15 pm Dec 29 2020

As far as I know this bike is pretty much stock other than the shock revalve that I had done and the exhaust. It came with this FMF Fatty installed but I also have the original pipe in excellent condition. Am I correct that the original pipe would be double walled? Any opinions on the Fatty? What kind of gains is it designed for?
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It also has this FMF Turbine Core silencer/spark arrestor but I also have the original silencer in excellent condition. Any thoughts on which to use? Will the factory silencer be more quiet?
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I also got a box full of parts for this bike when I bought it.
Mostly maintenance items. Suspension linkage rebuild kit, brake pads, a variety of sprockets, extra chain slider, shifter, air filter, kill switch, gaskets, seals, wheel bearings, throttle cable, spoke set, and assorted other items. The bike doesn’t need any of this right now but it’s nice to have it on hand. I won’t have to buy any sprockets anytime soon. lol
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I need to get it outside and wash the barn dust off of it before I get to work but right now I’m looking at my options for some plastic and I need to figure out what I want to do with the seat.
The cracked tank remains my problem. I ordered some 1/4” thick polyethylene stock and I’m thinking about maybe adding it to the petcock area and plastic welding it around the perimeter. We’ll see.

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Re: 1992 KDX200 project

Post by KDXGarage » 11:41 pm Dec 29 2020

Look through some old threads (like REAL old). Someone posted pics of the interior of the stock pipe. It is indeed double walled.

Stock spark arrestor SHOULD be a touch quieter.

Yes indeed! A lot of parts there!
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Re: 1992 KDX200 project

Post by Goofaroo » 04:01 pm Dec 30 2020

It’s been so long since I rode this bike I am really curious to get on it again. I only rode it for about 15 minutes but it was on some pretty technical singletrack and all I recall is that I really liked it. It was very comfortable, handled great, and very useable and linear power. I love my XR and my 87 KDX but I have a feeling this will be my first choice when I hit the trails.

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Re: 1992 KDX200 project

Post by KDXGarage » 05:25 pm Dec 30 2020

I edited your picture post to get the pictures and words lined up.
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Re: 1992 KDX200 project

Post by Goofaroo » 08:42 pm Dec 30 2020

Thanks! I’m technology challenged. lol

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Re: 1992 KDX200 project

Post by Goofaroo » 03:07 pm Jan 11 2021

I’m toying with the idea of adding this Acerbis Nost fender extension to the stock fender. It would require just a slight amount of trimming on the original fender and the extension. I have a white Nost front fender that I was planning to use but I’m kind of torn on what to do. I was thinking I was going to put white radiator shrouds, white handguards, and the white Nost fender with the blue extension on it. Then I found out that it ain’t easy to find white shrouds. These projects are always a puzzle.

A new seat cover is on the way so that’ll eliminate the pink splatter on the seat. I went through the carb and got it reinstalled. Still gotta fix the tank. Working on this has been slow due to changing out some doors in the house and maintenance on some of my other bikes but it’ll be up and running before too long.
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Re: 1992 KDX200 project

Post by KDXGarage » 04:56 pm Jan 11 2021

That would be one super wide fender! I like the two-tone, but with the stock wide fender, it really would be a bit too wide in my mind.
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Re: 1992 KDX200 project

Post by Goofaroo » 05:38 pm Jan 11 2021

It’s actually not much wider than stock and not wider at all towards the front. On the Nost fender it is pretty much the same width as stock. Not sure what I’m gonna do but it’ll be mounted on either the stock fender or the Nost. I was at the ISDE in Tulsa back in 94 and was drooling over the bikes from the Euro teams. I’m just trying to create the same vibe. To me the older bikes are a lot more stylish than the new ones. I used to go to the bike shops and look at all the bikes I would love to have. Now I don’t even go. The only new bike that appeals to me is the Africa Twin. Other than that I couldn’t care less.

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Re: 1992 KDX200 project

Post by Goofaroo » 03:54 pm Jan 14 2021

A couple of small victories today. In the interest of getting rid of the pink on this scooter I had taken the swingarm stickers off and today I got the new uni-track stickers in the mail. I also came up with a solution for routing the odometer cable through the headlight bucket. I had this angled grommet in my rubber drawer and it worked out perfectly. I can check that off the list.

I’ve been in contact with Acerbis for some of their hard d to find plastics but also my Elba didn’t come with a bulb. The guy at Acerbis told me that he was aware of this issue. The ad description leads you to assume it comes with a 12v 35watt bulb but it doesn’t. All he could do was send me a link to the correct bulb on Amazon so I have a couple headed my way. Then I can get the wiring harness modified and be done with the lighting.
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Re: 1992 KDX200 project

Post by Goofaroo » 07:36 pm Jan 16 2021

Started tinkering a bit with the front fender. I think I’m going this direction on the fender. Still waiting on a few more parts and I need to address the tank. Once I get it on the trail I’ll be able to figure out what I want to do if anything with the suspension and ergonomics. I can’t wait to give it a whirl.
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Re: 1992 KDX200 project

Post by KDXGarage » 09:27 pm Jan 16 2021

Looking good.

The forks came with 0.30 Kg / mm rate springs. I am strongly suggesting you look into stiffer springs to meet your needs.
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Re: 1992 KDX200 project

Post by Goofaroo » 07:38 am Jan 17 2021

KDXGarage wrote:
09:27 pm Jan 16 2021
Looking good.

The forks came with 0.30 Kg / mm rate springs. I am strongly suggesting you look into stiffer springs to meet your needs.
At this point I don’t know what springs it has. I’ll be able to make suspension mods once I get it on the trail and see what happens. I may need new springs front and back.
It’ll be interesting to get it all assembled and set the shock sag and see where it stands.

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Re: 1992 KDX200 project

Post by Goofaroo » 06:00 pm Jan 17 2021

I decided on the Nost fender so I drilled it and mounted the extension. I still need to drill the holes to mount the fender. I added some decals to the shrouds and spent a while with a heat gun getting the original backgrounds off of the side covers. I’m not sure if I’m going to use background material or tape off the side covers and paint the backgrounds. Still waiting to on parts as usual with these projects. Not much of an update but here it is.
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Re: 1992 KDX200 project

Post by KDXGarage » 06:14 pm Jan 17 2021

That looks good. You even got the stickers straight. That is not an easy job. :-)
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Re: 1992 KDX200 project

Post by Goofaroo » 01:54 pm Jan 18 2021

Today I found the Acerbis fender brace that I have been searching for so I’m not going to drill this fender until I have the brace in hand.
I also brought my 87 model into the shop to do a oil and brake fluid change. I want it ready to go when I get the 92 going. I’ve got a friend that’s jonesing to hit the trail with me.

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