2004 KDX 200 Rebuild

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GATOROC
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Re: 2004 KDX 200 Rebuild

Post by GATOROC » 01:21 pm Mar 22 2019

Vossman and TwistedRoot - thanks for the info on getting your cylinders replated. I just sent mine off to PowerSeal today. Three weeks is a bit to wait, but I'm sure it will be worth it.
2000 KDX 220

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Re: 2004 KDX 200 Rebuild

Post by Vossman » 02:55 pm Mar 23 2019

Glad it helped, you will be pleased. You just rebuilding the top end?

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Re: 2004 KDX 200 Rebuild

Post by GATOROC » 05:49 am Mar 24 2019

Yeah, just the top end for now.
2000 KDX 220

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TwistedRoot
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Re: 2004 KDX 200 Rebuild

Post by TwistedRoot » 06:26 pm Mar 25 2019

I was able to get out for a quick ride today and I can def say WOW. A good deal more power and torque throughout. I have only had the bike for a year and a half so Im not really used to the engine, but obviously it is a big improvement over the 17 year old top end. For now I will order up an FMF Gnarly Desert pipe but after that Im done for a while I think, lol. :mrgreen:

Gatoroc: Hey your welcome but I just parachuted in here for all the great info! Lots of good tips to make sure you do it right the first time!
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2002 KDX 200
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Re: 2004 KDX 200 Rebuild

Post by KDXGarage » 08:19 pm Mar 25 2019

SHARP!

Good job on feeling fresh power!
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 09:47 pm Mar 26 2019

Ya, that looks great. I think the Gnarly will be a good addition. Thanks for the pic.

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Re: 2004 KDX 200 Rebuild

Post by Vossman » 05:35 pm Mar 27 2019

Need a little help. How do you measure the friction plates or more specifically where? On the red arrow measuring distance from the fiber and the disk or the blue arrows measuring fiber to fiber? Fiber to fiber they are within limits but either way I should replace the set. What do you guys think, Tusk, EBC or OEM?
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Re: 2004 KDX 200 Rebuild

Post by Molly's 70 » 06:42 pm Mar 27 2019

Blue arrow. Measure the thickest part.
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Re: 2004 KDX 200 Rebuild

Post by KDXGarage » 09:27 pm Mar 27 2019

Yep, I second him.

The friction material is on the plate. No need to measure the plate. The concern is how much material is left.
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Re: 2004 KDX 200 Rebuild

Post by ericr » 10:02 pm Mar 27 2019

I bought the Tusk plates and they work just fine. Others have reported the same. We'll see how long they last. I combined them with OEM clutch springs. I had read that there's no need for HD springs, even with mods, as all they do is increase clutch pull effort. I appreciate the updates and photos!
'02 KDX 200, '02 KDX 220 - My restoration thread... viewtopic.php?f=77&t=22266

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Re: 2004 KDX 200 Rebuild

Post by John_S » 05:04 am Mar 28 2019

I'm excited to see this bike start to come together. Thank you for documenting your progress. I also use a Tusk clutch and went with new OEM springs. Its got 60 hours on it and no complaints.

My basket was notched pretty bad when I bought the bike and it needs to be filed again. I'm going to install a ProX basket, dampers, and new clutch soon. I came across an OEM set (steels, frictions, and springs) still in the packages on Ebay for $70. If not for that, I would go with Tusk again.

If anyone is interested in a ProX basket...it does NOT come with the dampers like it shows on all the Ebay pictures. I had to get them from RMATV for $30. The dampers are listed under "Parts for my machine" for a 200 but they don't show up if you're looking at 220 parts.

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Re: 2004 KDX 200 Rebuild

Post by VTMTcowboy » 10:29 am Mar 28 2019

TwistedRoot wrote:
06:26 pm Mar 25 2019
I was able to get out for a quick ride today and I can def say WOW. A good deal more power and torque throughout. I have only had the bike for a year and a half so Im not really used to the engine, but obviously it is a big improvement over the 17 year old top end. For now I will order up an FMF Gnarly Desert pipe but after that Im done for a while I think, lol. :mrgreen:

Gatoroc: Hey your welcome but I just parachuted in here for all the great info! Lots of good tips to make sure you do it right the first time!
Great looking KDX!! Nice to see it plated as well.
1997 KDX 220
2004 KDX 200

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Re: 2004 KDX 200 Rebuild

Post by Vossman » 05:16 pm Mar 28 2019

John_S wrote:
05:04 am Mar 28 2019

My basket was notched pretty bad when I bought the bike and it needs to be filed again. I'm going to install a ProX basket, dampers, and new clutch soon. I came across an OEM set (steels, frictions, and springs) still in the packages on Ebay for $70. If not for that, I would go with Tusk again.
Tusk it is with OEM springs I guess. I’m not comfortable reusing these friction plates, very dark and some uneven wear. If I could get all OEM for $70 like you did I’d be all over that. Appreciate the info.

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Re: 2004 KDX 200 Rebuild

Post by Slick_Nick » 08:22 am Apr 06 2019

John_S wrote:
05:04 am Mar 28 2019
I'm excited to see this bike start to come together. Thank you for documenting your progress. I also use a Tusk clutch and went with new OEM springs. Its got 60 hours on it and no complaints.

My basket was notched pretty bad when I bought the bike and it needs to be filed again. I'm going to install a ProX basket, dampers, and new clutch soon. I came across an OEM set (steels, frictions, and springs) still in the packages on Ebay for $70. If not for that, I would go with Tusk again.

If anyone is interested in a ProX basket...it does NOT come with the dampers like it shows on all the Ebay pictures. I had to get them from RMATV for $30. The dampers are listed under "Parts for my machine" for a 200 but they don't show up if you're looking at 220 parts.
I bought a new Pro-X basket off of eBay and it came with the dampers and all required hardware. I think you got jipped!
'00 KDX 220R

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Re: 2004 KDX 200 Rebuild

Post by ericr » 12:37 pm Apr 06 2019

When shopping for a Pro-X basket, look for the part number that ends in "-F". That's the newer forged version.
'02 KDX 200, '02 KDX 220 - My restoration thread... viewtopic.php?f=77&t=22266

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Re: 2004 KDX 200 Rebuild

Post by John_S » 01:58 pm Apr 06 2019

Slick_Nick wrote:
08:22 am Apr 06 2019

I bought a new Pro-X basket off of eBay and it came with the dampers and all required hardware. I think you got jipped!
If you paid $170 for yours then yes I got jipped. Since it was the "F" basket and the dampers were $39 ($209 total) I ended up saving money. It seems like the norm on ebay is $222. It was more annoying than anything but while shopping for the basket I came across a set of OEM steels, frictions, and springs, new in the packages for $75. It all ends up working out, no jip.

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Re: 2004 KDX 200 Rebuild

Post by Vossman » 09:45 pm Apr 09 2019

Finally got the clutch disks and springs and finished the water pump seal. I’ll soak the disks and install the clutch and side cover tomorrow if I can.
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 07:23 pm Apr 11 2019

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Clutch is put together and so is the right side cover. Had a shouldered washer under the shift shaft move when assembling so the case wouldn’t close because it was to high up. Quick fix though. Also had to push the kick start spring deeper into its hole to go under the little tab in the case. Things move smooth and shift fine. The rest will go together this weekend.

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Re: 2004 KDX 200 Rebuild

Post by KDXGarage » 09:33 pm Apr 11 2019

Looks good!
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Re: 2004 KDX 200 Rebuild

Post by ericr » 05:00 pm Apr 12 2019

Looks good. As an alternate assembly option, I installed the clutch before installing the inner clutch cover. You can use some washers under the clutch spring bolts to lock up the clutch and then put a penny between the primary gear teeth and clutch to torque the clutch nut. Turn the engine over, and you can torque the flywheel nut too without the need of a flywheel holder.
'02 KDX 200, '02 KDX 220 - My restoration thread... viewtopic.php?f=77&t=22266

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