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The paint is stripped during the process. They pretty much all look like that.

Understandable, I'm leaning towards clearing. I figure I'll do a cosmetic resto in the future and blast then clear the covers/ cases, guess this will give me a trial run to see how i like the clear vs silver paint.

For future searches:

This is a beautiful example of aftermarket plating. Kawasaki OEM Electrofusion coating does NOT have the well pronounced cross-hatching shown here.

I was a little curious about that. Absolutely no sign of crosshatch when it came apart.
Tried to get some glamor shots: And as always, the pics don't do it justice.
Very painless transaction with millennium. The website that tracks the progress wasn't being updated but that didn't bother me with all that's going on with covid I'm not in a hurry. When i did inquire on the status they were very prompt with a response/ update.

Also want to give a huge shout out and thanks to chad at Sudco International. Very quick responses to all emails and questions. And i know some of it was from home and off work hours. Not expected but definitely appreciated!! I've dealt with them in the past and they're always friendly and helpful.

Thank you for the additional pictures.

I had a NOS KDX175 cylinder one time. It looked smooth. I have a NOS 1989 - 1994 cylinder somewhere. It looks smooth, too. My new 2005 KX250 engine's cylinder looks pretty much the same as your cylinder.

EDIT: I made a new thread. viewtopic.php?f=77&t=24283

Keep on keepin on you not at all alone working on an old Kdx I have alot invested in my 02 220 and it is because I love these bikes and I dont care what the orange bike riders say. i dont understand why Kawasaki doesent still sell these as other manufactures are making a killing on two strokes still. We all choose the bikes we love and enjoy riding I get great joy out of the fact that no one can quite figure what a KDX's is supposed to be a trail bike or a racer we know it's all the above! Looks like you are doing a great job there keep up the good work! Definitely want to see it when your all done
Happy trails

Making progress. Next time this will be a breeze lol. Also i do regret not blasting and clearing everything..... next time! Until then, full steam ahead Got her out for a little bath while i could get to the hidden bits, again, regrets on not powdercoating the frame and swingarm but i really was going for function. I'll do the showroom resto in the future.

And i made some headway on the forks, just need to decide on oil and get them back together.
Improvised a cartridge holder... and the twenty eight year old oil. Out with the old And in with the new!

QUITE LOVELY!

Awesome gif, too!!

Congrats on the Gold Valves!

Thanks! I appreciate all the encouragement. I'm gonna be honest and say that i never thought/ knew the original forks needed help, i just rode the thing lol. It has always been a woods machine and will continue to be, but i try to learn from the more experienced and figured that since it needed oil and seals, I'd try the gold valves while I'm there. I'm also excited to get it jetted correctly, i pulled my original carb and its got stock jetting, no wonder i fouled so many plugs! But at the time i just assumed the factory knew better than i did and didn't mess with the carb.

Side note, how does everyone find riding places these days? I've started looking around without much luck. Found a couple atv clubs that don't allow two strokes but not coming up with much else.

Well it's together!
Started the break in heat cycles, and left the rotor cover off because i am having trouble doing a final torque on the rotor nut. Well it looks like the left seal didn't take? There was oil on the ground, and some under the rotor. Quite depressing but it is what it is. I'll try pulling the rotor this weekend to get a better look.

Ok, upon further inspection, i have a crack in my fuel tank, perhaps it dripped onto the rotor? I'm putting a pan under it tonight and the rotor cover on.... Hopefully it'll help narrow down the issue

Are you kidding me! STUPID TANK!! It looks great from a afar to me!

You have done a great job on getting it this far. Don't stop now.

Ugh. Plastic gas tanks. Maybe you could use a plastic welder on that one?

I have recently stumbled onto superglue & baking soda to fix some plastic cracks on small stuff. Not sure how well it would work on fuel.

Interesting Goat, I'll have to look into that, i think being in the sun made it worse. I put some gorilla tape on it over night and it doesn't look like it leaked yet. I will be in the lookout for a good replacement tank. Fires on first kick and sounds so good when it's warmed up!

Sweet! Sure looks like a first rate job.

Nice looking bike!