My 87 KDX200 project.

Discussion specific to the various air-cooled KDX models sold in the USA
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kawagumby
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Re: My 87 KDX200 project.

Post by kawagumby »

The difference of the KX hub is the connection bolt size for the brake rotor, otherwise, I can't find any difference between the KDX and the KX hub - and the rotor is the same diameter. The KDX's both front and rear have larger rotor bolts than the KX's so if I have a good kdx rotor I want to use on a KX hub I have to tap the KX hub out to the larger size -
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
Goofaroo
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Re: My 87 KDX200 project.

Post by Goofaroo »

Your bike looks great. As you've noticed I'm also rebuilding a 1987 model. I'm with you as far as the comfort and riding position of the older bikes. I've spent some time on some newer bikes and I just can't get comfortable on them. I ride a 1985 XR350R and as far as I'm concerned it is the motorcycle of the century. Besides the older XRs, the only other bike of interest to me is the 86-88 KDX200. I'm going to end up dumping way too much money into this bike but I think it will make a great bike for my son and he hope he keeps it for a long time. I've had my XR350 for almost 20 years and I hope to have it until I can't ride anymore. I have taken a few trips to the Ouray area in Colorado and spent a solid five days pounding through rocks and my friends on their modern bikes and they are miserable in no time. I can ride comfortably all day on my old XR and it gets all the attention from other bikers we meet. It's also no slouch when I want to let er' rip. Anyway, it's going to be fun to kave a two stroke in the garage again and I can't wait to give it a whirl.
kdxluvr
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My 87 KDX200 project.

Post by kdxluvr »

This thing looks sweet!How is it running and handling?I had a chance to ride a clean 87 back in the fall.Amazed at how fast i could go in tight st on that thing.I have been wanting to build one up similar to yours.
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kawagumby
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Re: My 87 KDX200 project.

Post by kawagumby »

It's still going strong...I haven't been riding it enough due to some medical issues, but plan to put some serious hours on it this summer...It is a light and low bike, very good for the tightest stuff.
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
kdx87
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My 87 KDX200 project.

Post by kdx87 »

Looks amazing, those cutouts on the side fenders are the airvooled fenders?
Swill
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Re: My 87 KDX200 project.

Post by Swill »

What foot pegs have you got on that thing. Great looking bike BTW!
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Re: My 87 KDX200 project.

Post by hbgod »

Hey man what rear fender is that? i need a nice MX fender that will fit. dont mind doing modifications like new mounting holes and stuff.
If you ain't Mixin Gas, You ain't Haulin Ass!
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kawagumby
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Re: My 87 KDX200 project.

Post by kawagumby »

Hi guys,
Sorry it took so long to respond, but I hadn't checked this thread for a while....

The footpegs are Fastway pegs I originally bought for my 08 yamaha WR250R (dual sport), I didn't like them on that and it turns out they fit the 87 KDX with very little modification.

The fender is an 86 kx125/250/500 rear: Maier Mfg Maier 145023 rear fndr kx125/250/50 grn Green M14502 65-4502 MM145023
Some trimming, but I installed a curved flat aluminum mounting brace (1/4 x 1" you get at the hardware store), threaded in the middle to attach fender and bolted to the existing frame end point holes. If you look at the pictures you can see the screw head. It works pretty well.

I'm still riding the bike often and continue to tweak things here and there. It's a different experience than the newer bikes and is fun to ride.
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
Hail seizure
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My 87 KDX200 project.

Post by Hail seizure »

Cool bike! Mine is a 1988 C3 UK Model. You have inspired me to upgrade my bike too.
I found a 1988 KX rear wheel and brake assy on eBay. The KX carrier slides straight in
to the stock swinger with no mods. All I need now is to make up some new spacers to
mount the KX wheel in the middle. How did you mount the master cylinder to the frame?
Also did the YZ yokes(you guys call them trees) fit the KDX headstock or did you have to modify them.
Cheers Mike.
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kawagumby
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Re: My 87 KDX200 project.

Post by kawagumby »

Hi,
Wow, getting that 88 KX rear wheel and brake ass'y was a great move! I used a YZ master cylinder that has a built-in reservoir and mounted it to the KDX frame with a plate I welded on.
The YZ yoke (triples) require the KDX stem to be pressed in. This is the same as most USD conversions with the KDX stem needing to be knurled to gain a few thousanths of an inch width for proper fit. I recommend using the stem from an E or H model, they work better than the stem of a C model - the bearings are the same size. As with any upgraded yoke & forks, the steering stop needs to be modified also.

Good luck with your project! Be sure and post some pictures :grin:
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
pkenney
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Re: My 87 KDX200 project.

Post by pkenney »

Great project and thanks for sharing the good ideas.
Do you mean an 88 KX 125 rear wheel and brake or KX250?
I am working on an 86 and was planing to replace the worn out stock rear hub.
The hub around the sprocket side bearing retainer clip is worn and I'm not confident that the clip will stay in place.
After reading all the info here I may as well upgrade instead of wasting money replacing the stock parts.

Many thanks for the inspiration
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kawagumby
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Re: My 87 KDX200 project.

Post by kawagumby »

It was Hail Seizure that used an 88 KX rear ass'y to upgrade his bike. I used a 2001 KX125 wheel and rotor with an H model caliper as noted earlier in this thread. The only drawback of the earlier KX model which evidently bolts right up would possibly be availability.
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
pkenney
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Re: My 87 KDX200 project.

Post by pkenney »

Thanks, maybe he will reply...
Great looking KDX, even zoomed way-in everything looks factory done.
87KDXTIMP95
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Re: My 87 KDX200 project.

Post by 87KDXTIMP95 »

Hey Kawagumby, sorry to post on an old thread.. and as a disclaimer.. I'm pretty new. But I have an 87 KDX 200 as well and I am curious about the YZ250F fork swap. I'm looking to do the same to mine and wanted to see if there were any fitment issues or specifics you could help me out with? All Balls bearings? Any Bushings? Any info would be greatly appreciated.
01 KDX220--86 KDX200--07 YZ450F
Dear Kawasaki,
Please bring back the KDX!
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kawagumby
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Re: My 87 KDX200 project.

Post by kawagumby »

Hi,
No unusual problems fitting the YZ forks (or WR for that matter - WR250 forks wouldn't likely need a revalve). You would need to use an E or H model stem (they are the same) pressed into the yz/wr triples. The C model stem might work but I felt it would be a hassle with the different top setup. The bearings are the same as the H model. Rather than a bushing, I used heavy aluminum sheet (cut from kitchen aluminum pie-pans etc. and simply wrap the aluminum the right amount to take up any space. The overall stem height is right on with no need for a bushing vertically - the H stem length is perfect with the YZ triples leaving just a few exposed threads with the nut in place. You will need to weld a wider turn stop to the KDX stop to keep the forks from hitting the gas tank.

Hope that helps.
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
scriberman
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My 87 KDX200 project.

Post by scriberman »

Nice bike, I'm doing similar. I wanted to keep conventional forks so have machined parts to fit Yam YZ 04 internals to standard forks. What valving did you decide on? I've also machined the rear shock to fit. I used a KTM rear wheel/disc/caliper for rear disc conversion. One spacer needed, caliper bracket small machining and no mods to swing arm.
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kawagumby
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Re: My 87 KDX200 project.

Post by kawagumby »

What an interesting approach to modifying the forks. Let us know how it works out!
Here's the compression stack I used to get the yamaha YZ forks working well for my riding skill level and terrain area:

24 x .1 (2)
20 x .1
16 x .1 crossover
22 x .1
20 x .1
18 x .1
16 x .1
13 x .1
11 x .3
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
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Bonno
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Re: My 87 KDX200 project.

Post by Bonno »

I bought a 87. Rough shape. I'm not a big dirt guy yet. I did ride a lot when I was younger. Pw50 to a blaster. 14yr old i road a 100$ 1977 IT 400. First bike since high school. I bought it then after really digging into the motor I wasn't sure I wanted to rebuild. The parts seem to be getting hard to fine as far as the cylinder. I found after reading there hope on welding and plating. Think all I NEED is a air box cover, speedo cable that's cut, fork seals, top end, and a cleaning. Oh and some grips. May of been better suited to just buy a running bike but I can work on stuff. I paid 175$ for mine. Maybe too much. Frame and tired and rims look good. Plastic not cracked or majorly scratched
rides gone... Yamaha 1991 PW50, 1977 IT400, 1984 700 Virago, 2010 Harley heritage, 1987 KDX200

Current bikes... Suzuki 1978 GS750 x2, 1993 KDX200
ClintNewkirk
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My 87 KDX200 project.

Post by ClintNewkirk »

Just curious, and maybe looking through the thread I missed it, but what mods were done to the front end to add the suspension? I'm about to start a build and love the inverted forks.
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Re: My 87 KDX200 project.

Post by ClintNewkirk »

kawagumby wrote:Hi,
No unusual problems fitting the YZ forks (or WR for that matter - WR250 forks wouldn't likely need a revalve). You would need to use an E or H model stem (they are the same) pressed into the yz/wr triples. The C model stem might work but I felt it would be a hassle with the different top setup. The bearings are the same as the H model. Rather than a bushing, I used heavy aluminum sheet (cut from kitchen aluminum pie-pans etc. and simply wrap the aluminum the right amount to take up any space. The overall stem height is right on with no need for a bushing vertically - the H stem length is perfect with the YZ triples leaving just a few exposed threads with the nut in place. You will need to weld a wider turn stop to the KDX stop to keep the forks from hitting the gas tank.

Hope that helps.
YUP I missed it. thanks! BTW this bike is amazing
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