1988 KDX200 build thread : The gift that keeps on giving (me headaches)

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KDXGarage
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

Ha ha. It can develop like that!
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

Little bit of an update on the Build:

I managed to source enough spare spokes and nipples from a fellow KDX enthusiast on ebay to continue forward with the project. I decided to try wire wheel and polish each of the spokes and nipples since I had already started down that road. **WARNING** do not ever try and attempt that because it is a huge time suck and can be endlessly frustrating. Better off just buying all new spokes and nipples or for that matter just get new rims. I did save some money but I probably spent more time than I should have and lost money in that area.

Removing old rusted bearings has got to be one of the most frustrating, time consuming, and lack luster parts of a build that I can think of. There is zero glory in it and it just feels like you are a complete idiot when the damn things won't come out. I had to "manufacture" some of my own tools and devices for the project because using punches, hammers, an blind bearing pullers just wasn't working too well. I would definitely suggest soaking the hubs in a tub of WD40 or penetrating oil overnight and then using heat on the hub if you think that the bearings might be rusted. These KDX hubs can be a real struggle...

I also ran into an issue putting on the clutch cover where I decided to try and use my press to "gently" put it back on the last bit of the way and cracked the case. I attempted to patch and conceal the crack only to have it split even worse when I was tightening the bolts down the next time I tried it. Looks like now I have to buy a new clutch cover or have a welder repair it. Either way its a huge PITA and was a real motivation killer.

Hoping to have this thing on wheel soon and hopefully have the engine on the frame. The last part of this will be finishing up the original seat and trying my hand at coming up with a decent paint job using spray cans. I know... spray can jobs don't look good on plastic. But I've done enough research and had enough success in the past to where I think I can actually pull it off and am more curious to see how it turns out.
Attachments
Lets not even get started on how hard bearing replacement was
Lets not even get started on how hard bearing replacement was
20200924_223056.jpg (4.21 MiB) Viewed 4485 times
20200928_221759.jpg
20200928_221759.jpg (3.63 MiB) Viewed 4485 times
what the original front rim looked like w rusted spokes
what the original front rim looked like w rusted spokes
20200928_200641.jpg (3.66 MiB) Viewed 4485 times
Finished product after way too many hours polishing
Finished product after way too many hours polishing
20200928_221754.jpg (4.28 MiB) Viewed 4485 times
Hub spray painted with Duplicolor chrome
Hub spray painted with Duplicolor chrome
20200909_221155 (1).jpg (3.06 MiB) Viewed 4485 times
TheGarBrah
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

more photos
Attachments
cracked clutch cover after some metal filler
cracked clutch cover after some metal filler
20200911_121259.jpg (3.08 MiB) Viewed 4485 times
inside of the cover
inside of the cover
20200911_121306.jpg (3.16 MiB) Viewed 4485 times
Rust and dirt inside the hub that I had to fight
Rust and dirt inside the hub that I had to fight
20200924_223100.jpg (2.99 MiB) Viewed 4485 times
chipping inside the rim
chipping inside the rim
20200905_173550.jpg (2.96 MiB) Viewed 4485 times
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

Lots of fun!

I hope you chunked that rim onto the recycle pile. :-)
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

I actually decided to keep the rim since it didn't seem to have structural damage, I shaved the broken bit down and reinforced the section with metal filler. If it cracks then oh well.. more curious to see how this things holds up. I'm trying to see how to keep costs down while on this project since I just keep running into issues that are getting more and more expensive and I've still got to deal with painting the plastics and doing all the electrical components.

This thing should be a legit rolling chassis very soon, and I'm getting excited to finally at least have all the skeleton buttoned up and then be able to focus on the motor and cosmetic stuff.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

That is right by the rim weld, which has a crack on each side. GULP!!

Have you considered sanding the plastics and buffing them out instead of painting them?
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

I have sanded the plastics and and tried buffing, but the coloring is not uniform and it looks off. I'll probably do a detailed documentation on that part of the build. But for now I'm just trying to get this thing put back together and then I can focus more on the looks and getting into the details.

As for the rim, I know that its on borrowed time. Won't be doing anything too wild on this bike for the time being and I'll probably upgrade both rims after this is all back together. But for now it is what it is.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

Just to give some idea about the condition of the plastics. The gas tank has been sanded down to 80 grit and I did a light bit of buffing on with the scotch brite pad. The different is minimal and I don't think the pad is going to cut it.

The front fender was painted with a spray can duplicolor engine enamel green once upon a time back in the early years of this build. The result was pretty damn good IMO considering there was not much prep effort put in and just adhesion promoter, primer, and the paint with clear.

This time around I plan on using SEM specific flexible primer , along with evercoat flexible filler to patch up uneven spots, and sealer. I'll probably go with a JP kawasaki green spray color and then finish it all off with Spraymax 2k clear coat gloss.

If it looks halway decent and shiny I'll take it as a win. I don't think spending hours on the polishing wheel or attempting to buff these plastics is going to look good or be worth the time.

I could always buy new plastics but... The thread is titled as such for a reason. I'm a glutton for punishment.
Attachments
20201014_210445.jpg
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20201014_210428.jpg
20201014_210428.jpg (3.17 MiB) Viewed 4432 times
front fender painted with duplicolor engine enamel spray can paint.
front fender painted with duplicolor engine enamel spray can paint.
20201014_210421.jpg (3.82 MiB) Viewed 4432 times
Plastics un painted
Plastics un painted
20201014_210410.jpg (2.99 MiB) Viewed 4432 times
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

You might want to watch the youtube video of the guy working on a red tank. He started with 220, then went to finer and finer grits.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by lucy »

As an initial step, I have used a razor blade to scrape off the outer plastic surface with excellent results. Just have to lean the blade backwards a little so it scrapes and doesn't cut into the surface. You gotta' get all that white oxidation off.

As K-Gar proffered, using progressively finer grit paper will get all the sanding marks out. My final effort included wet sanding with grits as high as ?1200(or higher). Then hit it with a heat gun(carefully) for the final polish.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

As far as the plastics goes, I've tried to the sanding and heat gun technique with poor results. These plastics are so bad that it would be almost impossible to get them looking uniform. The heat gun does work but has a tendency to be uneven and can cause melting very quickly.

Posting some updates on my build. Finally got the engine put together and new piston in. Had some issues waiting on various parts and pieces that were missing . Will be installing the engine back on the bike over the weekend. Sending my flywheel and stator off to FRP racing because the magnets had fallen off the original . With regards to the rear brake guard does anyone know how it should be attached ? It looks like it needs a spacer or maybe mine is bent ?
Anyone know if there should be a spacer here ?
Anyone know if there should be a spacer here ?
20201117_192144.jpg (3.05 MiB) Viewed 4274 times
Ordered materials for painting the plastics and I've already laid down the primer coat on them. So far I'm real impressed with the SEM flexible primer and I'm planning to be using the Evercoat polyflex to fill in any gaps and surface imperfections. Base coat will be PJ1 Kawasaki Green and I'll be using a Spray Maxx 2k clear .
Attachments
20201119_204404.jpg
20201119_204404.jpg (3.79 MiB) Viewed 4274 times
Engine finally assembled
Engine finally assembled
20201125_202615.jpg (3.38 MiB) Viewed 4274 times
Added more accessories and frame is 90 % complete
Added more accessories and frame is 90 % complete
20201119_192156.jpg (4.05 MiB) Viewed 4274 times
Finally a bare bones roller
Finally a bare bones roller
20201024_174459.jpg (2.93 MiB) Viewed 4274 times
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

Looking good. Here's a pic of someone who did an Armor All restoration.

EDIT ADD ON: Please note that the bolt head hits the top of the brake pedal, not the end of the bolt as the Armor Aller did. :roll:
ArmorAllRestoration.png
ArmorAllRestoration.png (689.84 KiB) Viewed 4270 times
Image
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

Thank you for picture KDX Garage . I've seen the exploded view diagrams and just wondered why I was seeing a gap between the portion on the top. It occurs to me that my bike may have the wrong part or a part from an earlier year...
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

Oh yeah! Some previous owner / Mr. Goodwrench may have "laid hands on it".
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

KDXGarage whose bike is that or where is that pic from ? Looks like a pretty clean motorcycle and similar to what I'm building
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

Someone on the internet trying to sell one, might have been an old picture. They were talking it up, but it has a gallon of Armor All on it.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by Goofaroo »

Here’s a couple of pics of my 87. You’ll have a lot of fun with yours when you get it done. Mine is stock other than a shock revalve and has been extremely reliable. It also draws a lot of attention on the trails. Everyone seems to have fond memories of these old bikes.
5F9D10C9-9ACA-4B78-B1B0-6C93C5290DC0.jpeg
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38288564-5422-4E93-8579-64627A1C7E03.jpeg
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

Nice Bike Goofaroo !

Quick question, does anyone know of any good rear chain slider options for the swingarm ? I can't seem to find enough info on what might work . Can I get one that fits on another bike like a KX and have it work ?
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

The one in front of the sprocket, at the bottom? frpoffroad.com He has made those plates for 30 years almost.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

No I meant the sliders that fit onto the swing arm . I don't know if they are all fairly standard of if the 88 kdx has some special requirement. Seems like this year every darn part on it is "unique" and "special" :rolleyes:
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