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

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

Post by TheGarBrah »

Made some more progress on the bike , just slowly dialing things in and filling in the details. Coil and Flywheel are coming back from FRP this week , and waiting on a laundry list of smaller parts to arrive .

Still a long ways away from being done but man does it feel good to finally get to this point ...
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

Looking good!
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TheGarBrah
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

As I've been putting the last leg of work on the bike , I was checking the coil against the stock requirements and noticed that the specs require .22 ohms to the primary and 7.22 ohms to the secondary. My coil is registering 1.1 ohms to the primary and 6.22 ohms to the secondary. I was wondering if this coil is definitely toast or maybe I could be measuring incorrectly. I think the terminal plug cap is missing so I measure the secondary by unscrewing the wire and measuring directly to where that wire plugs into the coil. I'm mainly wondering why the primary reading is so high.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by Pressingonward »

What does your meter read if you directly short the leads together? It might be that your meter or leads are adding a bit of resistance to the measurement.

I'm not sure what the tolerance is on the specs to say whether your coil is good or bad, but the readings do seem off.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

The reading on the multimeter is showing 0 ohms so I don't think its the multimeter. I'm also having an issue with the exhaust muffler. Seems like I've got a muffler from a KX model and I don't have a spark arrestor for it and Kawasaki seems to have different part numbers for each of the years so I don't know what should fit. Any ideas on how to solve that problem ?
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

Have you looked at an FMF universal spark arrestor?
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TheGarBrah
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

Here is what I'm talking about with the spark arrestor / baffle. Would be nice to stick with a vintage looking spark arrestor and this one is not looking like anything from kawasaki . Any ideas on how to get that faxtory MX look ?
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

A stock spark arrestor, a DG silencer, the FMF universal spark arrestor or another "made to fit, from another model" are your only choices I know of.

You might be able to find an Answer S/A-Pro spark arrestor that they stopped making 25 years ago. That or a DMC. Good luck on finding one of those.
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TheGarBrah
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

Thanks for the advice kdxGarage ! So I got the bike to spark and had to mess with the gear shifter a bit since it was put on backward, but when i was attempting go through the gears I noticed a problem so ended up taking it to my local bike shop and they said I probably have to split the cases again :vom:

So if I'm going to have to go through this ordeal AGAIN Im wondering if it might be worthwhile to upgrade my crankshaft since I've basically replaced and modernized every other single part on this bike. Any suggestions or recommendations ? I'm sure I can't go wrong with a wiseco but just want to see what other options would be appropriate since I'm already 3 years into this thing and have rebuilt it at least 3 damn times over already .
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

OMG!! Sorry to hear about splitting the cases again.

There is no Wiseco or other aftermarket crankshaft, replace with new OEM, used OEM or best, replace the connecting rod / pin / big end bearing/ thrust washers with OEM or aftermarket.

That is the same for ANY KDX. There is NO aftermarket crankshaft for ANY KDX, as best I know.
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

So after several months of staring at my bike collecting dust and feeling more than a little pissed about having to split the cases again I gathered up the muster to go for. Surprisingly it was not too difficult this time around .

I can't seem to figure out what is wrong with the transmission not being able to shift so I'm going to take the engine into my local mechanic and see if he can show me whats going on.

Fingers crossed I can finally get this bike running somewhat
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

Thought I would put some closure to this build thread for "The Riddler " . It was a Looonnnggg Summer.
So the issue I was having with the engine was a transmission failure due to the 6th gear being fused together with the output shaft. When I was rebuilding the bike the first go around I wasn't experienced enough to actually take apart the transmission and check each gear individually. That led to me just checking to make sure everything looked good and putting it back into the motor. I was able to shift through a couple gears but had no idea how to properly go through the gearing when the cases are split (Boy I learned how do that now!) . After taking the trans to a couple bike shops to see what the issue was I had no luck so I dug in and figured out the problem myself.

Once I figured out the problem I ordered parts and was out of town for a couple months so I put the project on hold. Once back, I had a renewed desire to finish the darn thing! I rebuilt the trans yet again, this time correctly and checked it out several times before putting the cases back together. The rest of assembling the engine was not too difficult. Once I got everything back on, I struggled a bit with some of the fine tuning. I was having issues with the clutch (found out I had the wrong torque specs for the clutch spring screws) and also the kickstarter would not spring back (The two markings on the kickstarter assembly where not lined up and the spring didn't have enough tension for it to recoil ).

Once I finally got the bike fired up and running I noticed what seemed to be a hole being drilled into the right side cover... Turns out the nut holding the gear on the main shaft had lodged itself loose and almost put a hole in the side of the bike.

So I slowly fixed all the hiccups and got it running on its own power now! Just need to add a few things like a silencer, some stickers, fix the vaccum problem with my front brake line, probably new tires, new rubber intake manifold, fine tune the carb, and get the shocks all dialed in.
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TheGarBrah
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by TheGarBrah »

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

Post by TheGarBrah »

The rebuild process and some of the follys along the way
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Re: 1988 KDX200 build thread : The gift that keeps on giving (me headaches)

Post by KDXGarage »

Wow! You have had some fun with this one! Great job to get back at it and get a long way further down the road.
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