'86 - Down the Rabbit Hole

Reference and discussion for the various air-cooled KDX models
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Re: '86 - Down the Rabbit Hole

Post by KDXGarage » 03:05 pm Apr 23 2019

Yes, indeed. I would suggest one consider researching safety goggles / side shields. While doing my buddy's 2007 YZ250 shock, I got shock oil in my eyes while wearing safety glasses. Fun times.
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Re: '86 - Down the Rabbit Hole

Post by Clatter » 12:09 pm Apr 29 2019

Oh, yeah.. Just having safety glasses isn't enough sometimes;
Use a face shield.
Have had to get stuff dug out of my eyes while wearing just glasses on a few occasions now.
Real men don't go to the eye doctor, just get a pair of tweezers and….!

Just another reason to cuss and throw tools!

Speaking of cussing and throwing tools...
The stupidest little details keep hanging me up, again and again..

Here, the brake line isn't the overall wrong length, it's that the housing and clamp area are in the wrong place. :evil:
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That makes it so things just don't work up top..
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Took a bunch of measurements and pics and sent them to the manufacturer,
Hopefully they will work with me on this one to get the right brake line.
Still.. PITA... :evil:

You will also see that there is a rebuilt caliper in the pics there.
The caliper rebuild kit was actually complete, and worked well.
Took me a few tries to get the puzzle assembled correctly using pics in the book.
When things sit apart for months, and you don't have one similar to compare to,
it gets a bit, um, confusing.. :hmm:

Master cylinder rebuild got me howling in frustration!! :cry:
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First, like always, ebay vendors are more than happy to sell you the wrong stuff.
All Balls rebuild kit is '89-up (as always).
I could use a couple of parts from it, like the boot and whatnot, but, of course, the crucial wear part, the o-ring, wasn't there.
The OG ring was save-able, along with most of the parts still there.
Cleaning out the inside with brake cleaner made the paint sticky and messed it up.
Finally ended up sanding down the little retainer clip to make it even fit together
(After prying and cussing and skinning my knuckles and scratching the paint).
The kit didn't include the cover seal, which was the thing i really needed most.

Finally, what was the real kick in the nuts was the lever. :kick:

You would think that you could just order a lever and bolt it on, right?
Nnooo.. Has to be a long painful dilemma.. :roll:

I woulda been happy to keep the old lever, but it was missing the travel adjuster stops - both 'in' and 'out'.
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Plus, the pivot hole was all wallered out because the PO had a screw in there instead of a shoulder bolt.
So, i got this other lever, and the return spring hole was too small, so i drilled it out,
And then the spring shot across the shop, to be lost forever..

Worst thing is, the reach from the lever isn't right to the master pushrod
(Even if i could drill/tap it for an extension stop)..
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Anyways, really, really, really frustrating work session..
I'm fully understanding now why nobody would ever restore a bike of this vintage.
Something simple like "I need a brake lever for an '86 KDX200" turns into this huge ordeal.

Parts aren't available, and what parts are available, are the wrong ones!
And that sure doesn't stop people from taking your money for them...

We'll eventually get this front brake working.. We will.. We will..
Even if it takes 50 hours!
Er, wait, make that 60..!
:toimonster: :toimonster: :toimonster:

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Re: '86 - Down the Rabbit Hole

Post by KDXGarage » 03:42 pm Apr 29 2019

Good luck with it, or improved luck.

Suddenly, I am even gladder to have my KDX hoard.
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Re: '86 - Down the Rabbit Hole

Post by Clatter » 04:47 pm May 06 2019

The quest for parts continues to grind along..


Anyhow, I'm on to doing something possible..
Really love my blasting cabinet, now that it is all sorted. :cool:
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it's looking like spokes might be hard to come by?
Hope this doesn't all just come to a dead end because of no spokes.

Anyone know where to look to match up some spokes?

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Re: '86 - Down the Rabbit Hole

Post by KDXGarage » 08:27 pm May 06 2019

Have you tried Buchanan?

Man! Those hubs look great.
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Re: '86 - Down the Rabbit Hole

Post by ericr » 08:55 pm May 06 2019

That looks really good. If you are not going to have the hubs painted/coated, I'd suggest Protectaclear. I used it on my raw aluminum and it's holding up well.

After spending untold hours trying to cross reference spoke lengths for Tusk and others, I gave up and ordered from Buchanan. It's a bit pricey, but they'll send you exactly what you need.
'02 KDX 200, '02 KDX 220 - My restoration thread... viewtopic.php?f=77&t=22266

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Re: '86 - Down the Rabbit Hole

Post by Clatter » 04:13 pm Jun 17 2019

Awlright.. Things are grinding along...

The petty brake fittings and pieces all eventually showed up on evilbay.
Getting the correct part numbers from partzilla, and plugging them into the evil search can net some results.
-Sometimes- the correct parts will actually arrive(!) :boogie:

Got all of those fiddly little brake lever pieces NOS one at a time over the course of weeks..

Greg at Off-Road Innovation also took the time to dig and find a bunch of little stuff as well.
Big thanks to Greg! :partyman:

He sent a selection of spokes that should be going into place a week or two.
Also said the crank/rod was done and shipping..

The front brake line was made at Galfer USA and sold on ebay (of course :lol: ),
But unlike these other vendors, they made right, and shipped me a correct line fee of charge. :cool:
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Additionally,
Another ebay vendor oem.replica made up a seat cover.
They didn't have any correct covers for the '86 KDX200, but were willing to make one if given an example.
I sent an OG tattered one off of the bay all the way across the world, and got back this cover.
It's 100% correct as far as i can tell.

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The upholstery shop put a little bit of extra pad around the perimeter fo the seat pan,
And made it look kind of 'puffy',
But it should look OK when the whole thing is assembled and broken in a bit.

We'll have to ride the thing and see.. :lol:

Hopefully, we'll have a little segment on motor assembly and wheel lacing in the next coulple of weeks.. :please:

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Re: '86 - Down the Rabbit Hole

Post by kdxsully » 04:31 pm Jun 17 2019

Love it.

Off Road Innovation is a staple in the market for these air cooleds. They’ve got so much cool stuff that doesn’t exist anymore. Good to know they can gather up the spokes needed.

I saw ORI sells a remanufactured crank for these bikes too, super cool.

How much did it cost to get that seat done, if you don’t mind? It looks phenomenal.
I like turtles

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Re: '86 - Down the Rabbit Hole

Post by KDXGarage » 05:06 pm Jun 17 2019

HECK YEAH!! Back at it!

The extra roundness on the seat might be quite helpful!

Here's a link with a couple of '86 pics.

https://www.motorcyclespecs.co.za/model ... 0%2086.htm

The seat really looks good. I think I bought a seat cover from them for a 1987 KX250.
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