2004 KDX 200 Rebuild

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Re: 2004 KDX 200 Rebuild

Post by KDXGarage »

Nice look into the inside of the electronic unit!
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Re: 2004 KDX 200 Rebuild

Post by Vossman »

So the clutch cover and gasket came along with the one part I was not sure about. The governor lever. The old one (on the right) had wear grooves and was bent so it didn’t sit parallel. I figured for $8 I would replace it. First start should be this weekend!

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Re: 2004 KDX 200 Rebuild

Post by Vossman »

kdxsully wrote: 07:34 pm Jun 29 2019 Got around to doing this on my ‘87.

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Take it apart, start removing the computer boogers (my magnet fell out of the spinner thing, don’t mind it).
This’ll show you where the wires and stuff are so you won’t break anything. Mine was dirty so I couldn’t see anything at all through the gunk. There’s a plate that sits on top of the wires, you’ll have to unscrew the screw holding it in and take it out first. You can see the hole where the plate was.

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Make sure you remove as much boogers as you can, they dissipate the heat you need to melt the solder on the circuit board. Press your iron on the contacts and gently pry up with a flathead at the same time; it’ll take a little bit.

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Replace your parts, cap the hole with a 3/8” rubber screw cap. Use a little silicon at the base for added sealing (I didn’t though). Really simple little job for a lot of cosmetic gain.
That’s pretty cool, thanks for posting that. Probably a huge $$ saver to have gone to a screw type mechanical setup. So is the odometer itself electronic? I have never seen this version.
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Re: 2004 KDX 200 Rebuild

Post by kdxsully »

Vossman wrote: 08:09 pm Jul 02 2019
That’s pretty cool, thanks for posting that. Probably a huge $$ saver to have gone to a screw type mechanical setup. So is the odometer itself electronic? I have never seen this version.
Here’s a link to one. https://rover.ebay.com/rover/0/0/0?mpre ... 2636858081

The computer itself operates off of a battery pack. The distance sensor itself I guess works a bit like a stator/magneto assembly. The magnet sits in a driver that has a slot in the wheel and every time it passes the computer it sends a signal to the computer.
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Re: 2004 KDX 200 Rebuild

Post by KDXGarage »

Vossman, VERY expensive unit in the mid 80's

Here's early mid 80's :

https://www.ebay.com/itm/83-85-KAWASAKI ... 7675.l2557

C series (and maybe 85??)

https://www.ebay.com/itm/1983-88-KAWASA ... SwHaBWkNgX

The left side shows mileage to the hundredth of a mile. Both sides are digital. The one on eBay is the only one I could find quickly. One side is missing the screen. If either side is black, it is DEAD.
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Re: 2004 KDX 200 Rebuild

Post by KDXGarage »

kdxsully's link is much better!

thanks, kdxsully!
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Re: 2004 KDX 200 Rebuild

Post by Vossman »

That’s kind of amazing. Pretty advanced for the time.
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Re: 2004 KDX 200 Rebuild

Post by Vossman »

FINALLY!

Spent the morning putting the covers back on, vital fluids in and final touches. Took 5 or 6 kicks then took the choke off and it fired up. Gonna do two heat cycles then first ride with 24:1 Amsoil Interceptor. Pretty great way to spend the 4th of July watching all that work fire up after a few kicks.

https://m.youtube.com/watch?feature=you ... uPVymZOGxc

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Re: 2004 KDX 200 Rebuild

Post by John_S »

Yes!! The bike looks great and sounds nice and solid. Thank you for bringing us along on the rebuild.
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Re: 2004 KDX 200 Rebuild

Post by KDXGarage »

HECK YEAH< Ring a ding ding!

Check the chain tension and throw a stiffer spring on there when you get around to it.
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Re: 2004 KDX 200 Rebuild

Post by Vossman »

Thanks guys. That chain does look tight when my fat butt sits on it. I thought it was plenty loose on the stand, guess not.
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Re: 2004 KDX 200 Rebuild

Post by ericr »

Looks great! Awesome job on the build.
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Re: 2004 KDX 200 Rebuild

Post by doakley »

Yeah, looks a little tight to me. Great job on the build!
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Re: 2004 KDX 200 Rebuild

Post by KDXGarage »

If I remember what I read correctly years ago, the chain is at it tightest when the swingarm is parallel to the ground. It might look OK when on the work stand or kickstand, but if it passes through the parallel area with it being tight, it gives the bearing on the output shaft a tight pull.
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Re: 2004 KDX 200 Rebuild

Post by TwistedRoot »

:busted: :supz: :bravo: AWESOME! Nice job!!
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Re: 2004 KDX 200 Rebuild

Post by KDXGarage »

All your hard work and time has paid off well! You have done a great job on your KDX! Thanks for taking us all along on the journey to where it is now!
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Re: 2004 KDX 200 Rebuild

Post by rungrandpa »

The bike looks great.
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Re: 2004 KDX 200 Rebuild

Post by GATOROC »

Congrats! Now it's time to go enjoy some mountain riding. :cool:
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