'86 - Down the Rabbit Hole

Reference and discussion for the various air-cooled KDX models
Pressingonward
Supporting Member II
Supporting Member II
Posts: 19
Joined: 08:09 am Jul 14 2015
Country:

Re: '86 - Down the Rabbit Hole

Post by Pressingonward » 09:01 am Nov 11 2019

Lookin good!

Clatter
Supporting Member II
Supporting Member II
Posts: 42
Joined: 05:23 pm Feb 06 2019
Country: US

Re: '86 - Down the Rabbit Hole

Post by Clatter » 02:40 pm Nov 15 2019

Thanks for the kind words fellas, and the help.
Takes a village...

"Danger seldom approaches without exciting a nerve ending someplace"
-James Bond

Couldn't sleep, so back apart..


Image
Image


One thing that was kind of itching, not really a problem, but an annoyance,
is that the earlier ('84-'85?) shock has a taller reservoir than the later '86-'88 shock.
It was paining me that I'd be cutting the lower shelf off of the holder bracket,
To allow room for the air valve at the top.
The whole thing is just too tall to fit in like it's sposeta.
Thought of getting a correct shock,
But,
At this point!?!? :doh:
We'll just have to trim and clamp well;
Fresh powder or not.
Had to ruminate on this one for a few weeks before commitment..
Image



Here's the main reason this thing came clear back apart; see how that wrist-pin retainer ring doesn't seat right?
It's not sitting clear down into the groove, all the way around..
With a $500 NOS cylinder, this just won't stand, man.
Image

So,
I go to put everything back together,
And it looks like some stroke on ebay sold me the wrong gasket set.
Big surprise there, huh? :roll:
Didja know the '84-'85 cylinder base has a different bolt pattern?
Image

Hopefully, the right gasket set will show,
and we'll get the thing together..


Last question..
How to get this chalky, dried-out ugly fuel tank looking better?
Tried sanding it down,
But,
Dag,
It's getting pretty thin before it's looking much better..!

Worried I'm going to sand clear thru to leakage.. :blink:

Anybody know where to get some Kawi green vinyl dye,
or..?

It's the LAST remaining ugly piece on the bike,
But it's a BIG one..

User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 10154
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: '86 - Down the Rabbit Hole

Post by KDXGarage » 03:50 pm Nov 15 2019

Look on youtube for the video of the guy with the red tank. Multiple finer and finer passes until buffing

Why is the piston pin circlip odd??
kdxrider.net forum member doakley participating in National Enduro series: (current class standing, 4th!)
viewtopic.php?f=136&t=23217&sid=e6a86d8 ... 9&start=40

Thank you for participating on kdxrider.net. :bravo: To post pictures here: "Full editor", "Attachments", "Add files", select the picture, "Open", "Place inline"

kdxsully
Member
Posts: 403
Joined: 08:28 am Apr 21 2019
Country: United States
Location: North Cackalack

Re: '86 - Down the Rabbit Hole

Post by kdxsully » 07:19 am Nov 16 2019

I have the same problem with my tank. One suggestion I saw is to use a heat gun to melt the plastic on the surface slightly, then even it out and polish.
I like turtles

pkenney
Supporting Member II
Supporting Member II
Posts: 61
Joined: 11:20 pm Dec 01 2013
Country: United States
Location: Cincinnati, Ohio

Re: '86 - Down the Rabbit Hole

Post by pkenney » 09:00 pm Nov 26 2019

My tank was really bad when i got it and was covered in an almost white oxidation.
I tried sanding it but got impatient took the drastic step of scraping most of it off with a razor blade held backwards.
I hesitate to recommend it but it worked for me and brought the color back but you still need to sand to get the smoothness.

I wish the tank stickers weren't so expensive!

Clatter
Supporting Member II
Supporting Member II
Posts: 42
Joined: 05:23 pm Feb 06 2019
Country: US

Front Brake Finished

Post by Clatter » 12:52 pm Dec 02 2019

A big thanks to 'pkenney' for the lighting coil and stator!

The legalization effort will be made just that bit easier. :mrgreen:
Legalize it!


With Mr. KDX200 here, this front brake caliper wasn't making any sense.
Trying the inner clip and parts different ways 'round - none seemed right.
Always this caddy-wompusness...
Image


Slept on it a few weeks, then took it apart with a fresh head and another look at the manual.
Finally made sense how it went together even though it doesn't really make sense.
(If that makes any sense..) :blink:


Bleeding these things is always interesting.
Takes me several ways stacked on top of each other no matter what vehicle.
I love my pressure bleeder,
But got away with gravity on this one..
Image


Using a one-way valve, -and- the hose end submerged made it -finally- happen.
Why this ends up being so difficult I'll never know.
in the end. I won! :lol:
Image

Clatter
Supporting Member II
Supporting Member II
Posts: 42
Joined: 05:23 pm Feb 06 2019
Country: US

Tank Resto

Post by Clatter » 01:07 pm Dec 02 2019

Here's what we did about the chalky white fuel tank..


First thing I did was get out a few sanding tools - Rolocs and a DA.
Image


It was raining out, so it gave me a chance to spend some quality time wrangling this thing..
Image
Image

My first go at it started off through the grits.
Up underneath where it wouldn't show.
The color started coming back easy enough,
But the chalky haze wouldn't go away.
It always loaded the paper right up and smeared it all around, not going away.
It ruined paper, then smeared the chalky residue around, all the while making deep scratches..
Image


So I tried the heat gun trick.
Worked in a chop shop way back in the day and saw a tank pop once.
The old man taught me that you keep the air moving through them to prevent fumes accumulating.
If you have air flow through, you can weld on a gas tank.
Figured I'd take this precaution using the heat gun..
Image

Didn't work for ****.
Melted a bubble spot, and with even more white chalkiness.
Spot right in the center of pic:
Image


What did work was rubbing compound on a wool buff.
Did a bit of finer-grit DA - like 220 or so,
Followed by some coarse Scotch-Brite,
Then finally the compound.
It didn't get the scratches out,
But at least the tank is green (enough) again.

Pics to follow..

Clatter
Supporting Member II
Supporting Member II
Posts: 42
Joined: 05:23 pm Feb 06 2019
Country: US

Final Assembly

Post by Clatter » 01:14 pm Dec 02 2019

And on to the finish line..

The reason the piston ring circlip was in crooked was my fault.
Built motors with Tru-Arcs and Spiro Locks lately,
And it just made my head wrong.
I tried winding in the retainer like a Spiro Lock, and bent it up so it never seated.

Guys at Wiseco were nice enough to send some gratis, as well as school me on installation.

They use a toothbrush handle (!) to get it all just inside of the hole,
Then a socket that fits the ID of the bin bore pushes it home square.
It clicked into place with a nice reassuring snap. :cool:


Once that was done,
Things just came together.

Image

Image


Fitting plastics and applying stickers is like icing a cake.

Image

Image

User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 10154
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: '86 - Down the Rabbit Hole

Post by KDXGarage » 06:17 pm Dec 02 2019

Look! IT'S A DIRT BIKE!

Great job with all the work and especially sharing the experience.

One day, a ride report is requested!
kdxrider.net forum member doakley participating in National Enduro series: (current class standing, 4th!)
viewtopic.php?f=136&t=23217&sid=e6a86d8 ... 9&start=40

Thank you for participating on kdxrider.net. :bravo: To post pictures here: "Full editor", "Attachments", "Add files", select the picture, "Open", "Place inline"

Molly's 70
Platinum Member
Platinum Member
Posts: 215
Joined: 04:29 pm Jun 18 2017
Country: United States of America
Location: Wichita, Kansas USA

Re: '86 - Down the Rabbit Hole

Post by Molly's 70 » 06:49 pm Dec 02 2019

Looks Awesome! I really like it. :bravo:
If you lend someone $20, and never see that person again, it was probably worth it.

Pressingonward
Supporting Member II
Supporting Member II
Posts: 19
Joined: 08:09 am Jul 14 2015
Country:

Re: '86 - Down the Rabbit Hole

Post by Pressingonward » 09:04 pm Dec 02 2019

Looking good!

kdxsully
Member
Posts: 403
Joined: 08:28 am Apr 21 2019
Country: United States
Location: North Cackalack

Re: '86 - Down the Rabbit Hole

Post by kdxsully » 12:05 pm Dec 04 2019

Looks new
I like turtles

Post Reply