1989 kdx 200 sr

[johnapp]

I have recently acquired a 1989 KDX 200 SR which I believe was a Japanese Import to the UK, I am currently restoring it with new more road oriented tyres , tank resprayed, calipers and front master cylinder refurbed and a thorough good clean, as the bike is in pretty good condition, having only covered some 6,300 miles from new, however, I have just hit a snag in that the rear shock (Kayaba) requires rebuilding and the suspension specialists have said there are hairline cracks on the bottom yoke, around the damping adjuster screw, which is correct, the specialists have said it needs the yoke replacing or repairing if it's possible?, apparently it may be a common fault with this shock and I am wondering how I can solve the problem, so I would appreciate input from members as to how I can overcome the problem. I rang an ebay site who had one and they confirmed there were cracks around the one they had when I drew their attention to it, so help would be gratefully appreciated. regards john

[KDXGarage]

Welcome to kdxrider.net. I think the best bet is to find a used, good condition shock with a good clevis.

Can you post pictures of your shock? (instructions in my signature)

Thanks!

[johnapp]

Hi thanks for the reply and sorry about the delay in responding, I think that KYB shock is prone to cracking around the adjustment eye, a photograph would be difficult to show the cracks, because they are so fine i.e. one each side of the eye, I actually located one on ebay and once I asked the seller to look carefully around the eye he confirmed there had been some welding done on that one, so I am hopeful of some skilled tig welder who I will see shortly and ask his opinion, as a part the clevis and damper rod come as an item always assuming they,re available, on another tack the oil pump (which looks as though its never been used ) has 2 marks (behind a rubber bung) which are slightly misaligned, I assume I adjust the cable until the 2 are aligned, obviously i,ll use mix initially, to confirm there are no air bubbles before switching to pump only. Look forward to your comments, i.ll post photos of the bike once sorted, only 6,300 miles since 1989.

[KDXGarage]

If someone TIG welds it, be aware that there is at least one o-ring inside the shaft, relating to the rebound adjustment rod. You might want to remove the clevis from the shaft. Be careful in reassembly to make sure the rebound is set properly.

I have no experience with the oil pump KDX's, so I may not be of much help.

[johnapp]

Hi Many thanks for the responses unfortunately the tig welder was aware there were o rings sealing the damper eye in and as such was unwilling to touch it because of the definite prospect of destroying the sealing ring/rings, the clevis has been removed completely, there are no clevis/damping rod assemblies in the UK/EU according to Kawasaki, so I would be grateful if there are any members out there who have a springy shock a good shock or even the clevis to rebuild mine, which is in good shape albeit the damping rod has very slight corrosion. I trust this is the forum to ask anyone about spares. Here's hoping

[johnapp]

[quote=KDXGarage post_id=215347 time=1617095401 user_id=6252]
Welcome to kdxrider.net. I think the best bet is to find a used, good condition shock with a good clevis.

Can you post pictures of your shock? (instructions in my signature)

Thanks!

Hi, Finally managed to suss out how to attach pictures of clevis which is the only part that's a problem the hairline cracks are visible but the suspension specialists won't refurb the unit with this clevis everything else is fairly pristine. regards

[KDXGarage]

Wow. That looks pretty bad! Drive on over. I will give you one. :-)

[johnapp]

Are you serious do you actually have one? the rest of the shock is in good condition, trying everywhere.

[KDXGarage]

I don't have one disassembled and handy. Since you are in the UK, it was just a joke. I don't have time and things set up to take one apart at the time.

I have a couple of shocks with bent shafts, so others will too. Look on eBay for a shock with a bent shaft to just get a good clevis.

[johnapp]

What a shame, I'm perfectly happy to pay postage and obviously for the part i'm even trying South Africa (unfortunately it was a 1995 which is different) I list on gumtree and check regularly on ebay but it's not easy. regards john

[johnapp]

Just a thought do any of the KDX rider fraternity have a shock with a bent rod but a good clevis, they want to sell, just wondering? regards john

[johnapp]

Does anyone know the length of the shock eye to eye, mines disassembled now so difficult to judge I've measured off the frame and it's 450mm can anyone confirm, the workshop manual doesn't say.regards John