1992 KDX200 project

[Goofaroo]

Here you go. I ordered two so I would have a spare.

I’m working on the harness to plug it in and I ended up ordering another on/off handlebar mounted switch so I can make use of the high/low beam function. I’m going to mount it down by the bar clamps and wire it to the high beam. The low beam will be wired to the original light switch by the throttle. I’ll be be able to run just the low, just the high, or both. It also has a festoon bulb socket for a parking lamp but obviously there’s no need for that so I just clipped off the wire going to it.

I was looking for a simple high/low switch but everything I found was too big and had horn and signal switches also.

[Goofaroo]

https://www.ebay.com/itm/Motorcycle-ATV ... %3A2334524

If you’re interested here’s the other switch I ordered.

[Goofaroo]

Not much to report because I seem to be in a perpetual state of waiting on parts. I finally received the fender brace and got the fender drilled and mounted. I also received the additional light switch so now I can build out the harness. I’be got it all laid out on my bench for testing and getting it all sorted so that it will easily plug into the bike. I always keep old harnesses and even buy them at swap meets. I have everything I need to color code the harness and give it a factory appearance.

It’s going slow but my search for certain parts has been time consuming. I’m basically trying to find parts that nobody wants anymore and have become obsolete. lol

Here’s a few pics.

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[Goofaroo]

I forgot this pic. This will be my high beam switch. I may have to move it inside the clamps if it interferes with the hand guards I’m going to use.

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[KDXGarage]

The brace looks good! Have you considered switching to black screws to match the fender extensions mounts?

[Goofaroo]

That fender is completely put together with the fasteners provided by Acerbis. The extension is “tacked” together with nylon anchors. You’re right though. Black screws would look good and I’ve probably got some around here somewhere.

[KDXGarage]

that or break out the Sharpie :-)

[Goofaroo]

A few more parts trickled in. I got white side covers and yellow number plate backgrounds. It’s a darker yellow than the headlight so I may try to find something closer in color.

I also received some handguards that I ordered and I don’t like them. They look too modern. I’m thinking about robbing the handguards off of my XR and putting the new ones on it.

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[ben990]

I don't know if I am copying you or you are copying me...

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[Goofaroo]

Lol. I guess we’ll have to ride together sometime. Great minds think alike.

Where did you get your number plate backgrounds? Were they pre-cut?

[ben990]

I got them pre-printed and pre-cut from factoryridedecals.com. Inexpensive, go on well, and last. I have them on several of my other bikes too.

[Goofaroo]

I got them pre-printed and pre-cut from factoryridedecals.com. Inexpensive, go on well, and last. I have them on several of my other bikes too.

I’ll have to check them out.

Were you able to get the bulb for your Elba? Have you wired it yet?

[Goofaroo]

If anyone is wondering if the UFO fork/disk guard for an H model will fit an E model. I took a gamble and ordered one. It fits fine but I had to drill a hole for the axle to come through, a small hole for a zip tie, and trim a little off to provide clearance for the brake hose.

The fork guard will also fit bit it will also need a bit of trimming to fit. I ran out of time but I’ll post a pic when I get it done.

Unfortunately I couldn’t get it in white unless I ordered 50 of them. Green will have to work. lol

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[KDXGarage]

Thanks for letting us know.

[Goofaroo]

Thanks for letting us know.

This style of brake/disk guard used to be available in assorted colors for almost any bike. Now they’re very hard to find. AcerbisUSA couldn’t even fix me up. I definitely would have preferred white.

It’s like I said; I like the stuff that nobody else wants anymore. lol

[KDXGarage]

Yep, I have NOS white and dark blue for 1988 KX somewhere in the hoard pile.

[Goofaroo]

Here’s the other side. I just had to trim the opening above the axle and fits perfectly. Another small victory. lol

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[KDXGarage]

Heck yeah. Looks good. Thanks again for showing they will work.

[Goofaroo]

I followed ben990’s tip on the number plate backgrounds. The tracking info on the shipping showed them as delivered but I couldn’t find them. After trying to deal with the post office and the supplier for a few days I went up to my mailbox with a snow shovel and found them about 6 feet from the mailbox buried in snow.
I took them to the shop and let them warm up. I was afraid the adhesive might have been damaged by the sub zero temperatures but they seemed to be okay. I installed them on the side covers yesterday and they seem fine. Another small victory.

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[Goofaroo]

I couldn’t find any handguards that looked right for what I’m trying to do. Back in the day I always liked the flat piece of plastic wrapped around the aluminum frame. They used to be fairly common and advertised in bike mags. A few guys had them when I was at the 1994 ISDE.

However; they have vanished. lol. I couldn’t even find a picture online. As usual I was apparently the only guy that still wanted some.

I took the green plastic off of the guards it originally had on it and used the aluminum frames and a sheet of 1/8” polyethylene to attempt to recreate them from memory. I used a heat gun to mold them to the frame. I have no idea how closely I came to the original but it gave me the look I was after.

I stuck the throttle side on there temporarily just to see how it looked before I finished the other side. I still need to install new grips and then I’ll put the bike on the ground and do the final install.

Here they are in all their glory. lol

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