It begins! '90 KDX200 rebuild

Post by **SS109** » 11:40 pm Jul 16 2011

dgraver wrote:id be interested to see an update of how the frame holds up after a few rides/months.. looks great though! good work!

I promise I will update on the durability of the paint with pics. I do a lot of riding/crashing so it will be tested!

Post by **Julien D** » 09:08 am Jul 17 2011

Lookin good man!

Post by **SS109** » 11:19 pm Nov 16 2011

Man, it has been a few since I have been able to really do anything with my 200. Today I changed that! Believe it or not but the acquisition of the '06 KX250F roller made this possible. I sold off all the accessories for the toy I traded for the roller which gave me enough for all my bearings, bushings, circlips, etc and they are on there way. I will finally be close to buttoning up my bottom end. From there it won't be long to having it completely done and back to riding!

I'll keep you all posted!

Post by **fuzzy** » 02:15 pm Nov 17 2011

I've been surprised by how well the PJ1 epoxy rattle can paint works.

Also, in your choices of black, beige, or white.... Appliance epoxy paint is awesome!

Frysk · Post by **Frysk** » 12:35 pm Dec 16 2011

Any updates ?

Looks like a nice project!
Also a question.. those white radiator shrouds and white sidepanels.. where did you get those ?

Planning to do some rebuilding on my "91 KDX.. And didn't seem to find them on ebay.

Post by **SS109** » 04:02 pm Dec 16 2011

Actually, there is a little progress to report. I got all my bearings, bushings, seals, etc. for the bottom. Just waiting to send the crank off to be rebuilt and then the engine goes back together! Hell yeah!

On the panels, the side panels came directly from Maier. Remember, any KX500 side panel from like '88 up is the same as the '89-'94 KDX. The shrouds I got from a fellow KDXrider member as he had one extra set.

Frysk · Post by **Frysk** » 06:18 pm Dec 16 2011

SS109 wrote:Actually, there is a little progress to report. I got all my bearings, bushings, seals, etc. for the bottom. Just waiting to send the crank off to be rebuilt and then the engine goes back together! Hell yeah!

On the panels, the side panels came directly from Maier. Remember, any KX500 side panel from like '88 up is the same as the '89-'94 KDX. The shrouds I got from a fellow KDXrider member as he had one extra set.

Nice, can't wait to see some pics

Panels from a KX500.. good tip :) I'll try looking for them
I think I'll just have to bump into some white shrouds.. It looks like they are kinda rare

Good luck and keep the updates flowing in!

younggunz · Post by **younggunz** » 11:13 pm Dec 16 2011

wow. this bike is looking good so far, im watching and waiting to see the finished product.

mann i just love my kdx only just recently got it, wish i could do this to it, that would be so fricken sweet

Post by **SS109** » 11:56 pm Dec 16 2011

You can do it. It took me a long time to be able to start the process and will be even longer to finish it but it will be worth it! Of course, it helps to have another bike to ride in the mean time. I picked up my KDX250 just because the price was so good on it ($450!) that I couldn't pass it up! Now, I love the 250 engine so much I decided to make a project out of it as well. Be watching for the first ever KDX250 aluminum framed conversion, using an '06 KX250f chassis I traded for, after my 200 is done!

turtle · Post by **turtle** » 11:57 pm Dec 16 2011

Yep it's gonna be a sweet looking machine.

KDX200-E2 · Post by **KDX200-E2** » 11:24 am Dec 18 2011

See'n as how I have a (small) vested interest in the completion of your
project. I too will be anticipating updates as you make progress.

Cheers.
Jeff

harlequin · Post by **harlequin** » 02:37 pm Dec 21 2011

Hey, awesome project! I just found this after joining a few days ago. I'm planning on doing some restoration to mine once I ride it around some.

+1 for the white and blue! will look very clean

Slick_Nick · Post by **Slick_Nick** » 08:12 pm Dec 26 2011

SS109, Give me a shout at nick dot Holinski at shaw dot ca when u get a chance. I'm in Marana for the week and would love to see the project in person if you have time!

Post by **SS109** » 02:29 pm Dec 29 2011

Sent my crank out today. I was going to use RB but a lot of guys from my club use Andrew Cooksey and swear by him, so, I thought I would spread the wealth a bit. He trues the crank to within .0005" and has super fast turnaround like RB. BTW, here is his website if anyone is interested: http://www.cookseycrank.com/#!

BTW, RB will still be getting plenty of my cash. I have my head to send off and will probably be buying a brand new carb from him.

Post by **SS109** » 10:01 pm Jan 02 2012

The crank guy let me know my crank was done and will be shipping out tomorrow. His communication has been excellent and his turnaround time is fast! So far I am extremely impressed with him. BTW, he sent pics as well.

Post by **SS109** » 06:54 pm Jan 05 2012

Crank arrived today. Double boxed, bubble wrapped, and all the old parts returned as well. It looks real good and might try putting my bottom end together this weekend!

jbowens2401 · Post by **jbowens2401** » 11:47 pm Jan 07 2012

andrew does great work

Post by **SS109** » 10:51 pm Mar 03 2012

rbates9 wrote:I am using a very old and tired craftsman oil less air compressor and it keeps up ok. 20? gallon.

I only filled it about 1/3 full and did a rear hub and a half the first time I tried it, it works a lot faster than you would think.

I'm not sure how the other one would work without using some sort of valve to slow the feed down or I think you would waste a lot of soda. If you try that one let me know how it works for you. When I have done the blasting it has been mostly small jobs so refilling the spot blaster was not an issue at all. Ask around, I bet you know some one that has one already you could try.

BTW, it is a very dusty job so you will want to be outside and away from things but the next day the dust will pretty much be blown away.

Well, tried out that cheap Harbor Freight spot blaster with soda media and it worked pretty good. I think there was more waste than I expected but oh well. Definitely messy! I looked like the kid from the movie "Powder" when I got done! No pics but I did the head and both wheel hubs and they look pretty good. I missed an area on the rear hub so I got to hit it again but will be getting things moving on the build really quickly now.

Post by **SS109** » 04:31 am Mar 04 2012

Started assembling my front wheel. Still need to true it but I'm too tired to finish it tonight. I laid the Tusk brake rotor on it to see what it will look like when done and I must say I think it looks sweet! Watchya guys think?

Post by **Julien D** » 07:38 am Mar 04 2012

^^^

Sexy! I dig the blue rim.

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It begins! '90 KDX200 rebuild