KDX200SR

Discussion specific to KDX models not sold in the USA
hi-def
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Re: 1990 KDX200SR

Post by hi-def »

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Re: 1990 KDX200SR

Post by Slick_Nick »

Those fork guards are interesting, I've never seen a translucent white set like that before.
'00 KDX 220R
hi-def
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Re: 1990 KDX200SR

Post by hi-def »

They are reproduction parts, they needed a little bit of tidy up from the manufacturing process but with how little they cost they are very good value.
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Re: 1990 KDX200SR

Post by hi-def »

A pic of how it currently is
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Re: 1990 KDX200SR

Post by KDXGarage »

Better run on down and pay up while you can!
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hi-def
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Re: 1990 KDX200SR

Post by hi-def »

Image

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Here is a pic of it out and about

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Re: 1990 KDX200SR

Post by KDXGarage »

Nice job on the bike. Terrific picture of the water!
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Re: 1990 KDX200SR

Post by hi-def »

Since the urgent job has been done I can now look at the engine. I know for sure it needs new crank seals but had no idea what condition the rest was in.
Early findings are promising, piston and cylinder look good other than being quite sooty, will measure them for spec soon. Powervalves move easily (without slipping) when the rack is moved, yet to see if there are any sheared pieces hidden below.

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Re: 1990 KDX200SR

Post by hi-def »

Looking pretty good

Image
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Re: 1990 KDX200SR

Post by hi-def »

I split the engine down further, has had a new Wossner piston at some point

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Made a thing to use with my bearing puller to split the cases

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Things of note: Everything looks good but the left hand crank seal and bearing were shot and at some point someone must have had trouble removing the right crank bearing as there is some damage that has been brazed up, the place rebuilding my crank are checking it currently.
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Re: 1990 KDX200SR

Post by KDXGarage »

The insides of those cases look super clean. What did you do?
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Re: 1990 KDX200SR

Post by hi-def »

I didn't need to do much, I only wiped a small amount of oil sludge from the very bottom of the cases, the rest I haven't touched. The crank is a different story, must have had some water in it at some point as the webs show spots of corrosion and so did the LH crank bearing.
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Re: 1990 KDX200SR

Post by KDXGarage »

Well that sucks!
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Re: 1990 KDX200SR

Post by hi-def »

Image

and with the gear removed

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vs standard (not my pic)

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Re: 1990 KDX200SR

Post by KDXGarage »

THANK YOU!! for the picture showing a difference to what many of us have seen 100 times over the years.
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Re: 1990 KDX200SR

Post by hi-def »

Almost finished the rebuild
I ended up replacing a couple transmission bearings as they weren't feeling 100%
Used freezer and oven to get them in

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Seals

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Crank bearings

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Re: 1990 KDX200SR

Post by hi-def »

Then used the hot slug method to install the crank

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Shims to centre the crank

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Gearbox in then left case half.

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Nice and centered

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Re: 1990 KDX200SR

Post by hi-def »

Didn't get to use the crankshaft puller I made as the heat method worked well.

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Bottom all back together

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Re: 1990 KDX200SR

Post by hi-def »

My new piston arrived so I got the rest of the engine back together and in the frame.
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No break in ride yet as I'm waiting on a replacement kickstart lever nut as the thread has been chewed up by a previous owner, I'll loctite the new nut on but will probably source a new shaft eventually.
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Re: 1990 KDX200SR

Post by KDXGarage »

Good job!
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