The World's worst 93 KDX Rebuild

[KDXGarage]

WOW. Quality workmanship on those side panels.

Larger bars taper from 1 1/8" down to 7/8".

[SerpentZA]

WOW. Quality workmanship on those side panels.

Larger bars taper from 1 1/8" down to 7/8".

Okay, fantastic now I know why there are so many fake bar guards and grips with the pro taper brand... damn the way those bars taper sure are pro

[SerpentZA]

More stuff arrived! Two pairs of seriously cheap grips, they're going to be chewed up anyway :)



They seem okay...



A bash plate from some unknown bike, I should be able to bodge it...



An air filter designed for a knockoff of a Honda... may work!

[Bitteeinit]

It's unfortunate that those plastics suck. I've bought some plastics off taobao before and they were fine. Seems like the guy making the KDX ones isn't well-equipped. Probably some guy in his shed. I went ahead and told some guys to try to make a left side-panel using the right one as a model... We'll see how it turns out. It'll be heavier, but oh well...

Nice to see those fork guards. I'm about to order these:
http://item.taobao.com/item.htm?spm=a23 ... t=5#detail
http://item.taobao.com/item.htm?spm=a23 ... t=5#detail
http://item.taobao.com/item.htm?spm=a23 ... t=5#detail
http://item.taobao.com/item.htm?spm=a23 ... t=5#detail

I like the last one most, but looking at those lines (especially the KDX), it looks like it might be for a 95+ bike. Nothing a pair of scisors won't fix. I guess I'll order two different sets and see which one I like best. Only 5$/pop. Do you have a link for those front guards?

[Bitteeinit]

Oh yeah, and since you're in China, you should try and get a set of wide aftermarket YZ pegs. I ordered a set and supposedly they've arrived, but I haven't heard anything yet (waiting for the call).

[ced64k]

Seems like the guy making the KDX ones isn't well-equipped. Probably some guy in his shed.

Here's his special technique

[SerpentZA]

It's unfortunate that those plastics suck. I've bought some plastics off taobao before and they were fine. Seems like the guy making the KDX ones isn't well-equipped. Probably some guy in his shed. I went ahead and told some guys to try to make a left side-panel using the right one as a model... We'll see how it turns out. It'll be heavier, but oh well...

Nice to see those fork guards. I'm about to order these:
http://item.taobao.com/item.htm?spm=a23 ... t=5#detail
http://item.taobao.com/item.htm?spm=a23 ... t=5#detail
http://item.taobao.com/item.htm?spm=a23 ... t=5#detail
http://item.taobao.com/item.htm?spm=a23 ... t=5#detail

I like the last one most, but looking at those lines (especially the KDX), it looks like it might be for a 95+ bike. Nothing a pair of scisors won't fix. I guess I'll order two different sets and see which one I like best. Only 5$/pop. Do you have a link for those front guards?

Do you mean the fork guards or bark busters? I'll post links for all this stuff if you like, I'll be working on the bike again tomorrow finally

[SerpentZA]

So it begins, I'm busy with other bikes, but I can do a bit here and there on TWWKDX(world's worst kdx)TM...

I took off the stator cover... hmm slightly oily water! Probably because there's no bloody gasket! Are those Philips screws normal?



Sorry, sad looking thing, I'll take it off later and try to clean it up...



Gross, spooge and a half! The KIPS cover also has no gasket!



See how the threading is cracked off? JB weld has been ordered from America... damn expensive! This engine will be 30% JB weld in the end!



That's just ugly..... can anyone tell me if anything is missing?



Apparently Chinese bondo is what's holding the engine together...

[SerpentZA]

Hmmm... thermostat seems to be missing... and no gasket again



Yep...



Darker than my ex-wife's soul... and that gasket has been reused... a few times



There's silicone gasket maker in the KIPS valves...



Well... This is going to be a task...

[KDXGarage]

NASTY! GOOD LUCK!!

[SerpentZA]

The piston looks pretty messed up, I don't have a way to hone or replate here, so I'm hoping the cylinder is good enough to just throw a new piston and rings in... opinions please...







I'm probably going to soak all this **** in petrol and use a toothbrush to clean it up as best I can... then call it a day.

[SerpentZA]

Almost forgot, reed valves look okay to me, intake manifold is perished, but nothing epoxy can't fix!

[SerpentZA]

WTF is this?



Any chance anyone can show me how this is supposed to look?

[sarrant]

From this thread by Keystone:


Your ground-up right subvalve would be the part center-left above the idler gear.

[KDXGarage]

OUCH

[Gotanubike]

That's one of your KIPS... Kawaski-Intergrated-Pebble-Stones...boosts top end

Actually it's just a broken off gear part of the valve and has tumbled around inside the motor and turned into a nice shiny ball

Sarrant's pic is of a brand new, or at least functional set . Here is a pic of a case similar to what you have.

[SerpentZA]

From this thread by Keystone:


Your ground-up right subvalve would be the part center-left above the idler gear.

Fantastic! Thank you! now I know what I'm dealing with... that entire kips system is a mess, I don't think I can salvage any of it... :P this will take a while, but this KDX will rise again, and be the best KDX in China!

[SerpentZA]

Found a ratty old destroyed engine for sale on taobao, the seller was willing to sell me these bits for 200RMB they are crap, but fixable, I'll try softening the plastic KIPS cover with a heat gun and try and to reshape it since it's all melted...



I got him to send me this just in case



Progress is slow but steady...

[Bitteeinit]

Do you mean the fork guards or bark busters? I'll post links for all this stuff if you like, I'll be working on the bike again tomorrow finally

Yes, please!


That cylinder plating looks like toast to me, but surely a local shop could get it sleeved for you?

[wolfracing38]

Those arent exacly "fake brand name" bark busters, Acerbis makes the best handguards money can buy, all the pro enduro guys use them....