Possible KDX 200 Winter Project

[eprovenzano]

I ride orange (KTM380) so don't flame me... but I'm looking at a what the owner thinks is a 97 KDX200 for a as a winter project. I've only seen a few pics, but based on the frame (round) and the upside down forks I believe it to be either a 93 or 94. The bike needs to be rescued. It currently does not run (owner says low compression). It's missing the fork guards, owner stated they are Pro-Action because they have a pro-action sticker on them... Both pegs are bent down. Not sure if something is bent, or the pegs need replaced... Missing radiator guards, it has a bald rear tire, the front is worn and I'm sure it hasn't been washed in a very long time...

Please school me on the virtues of the 94/95 KDX 200's. I know going in it need a complete top end. I'm just hoping the cylinder and heard are fine, clutch cable, radiator guards, fork guards (possibly fork seals) grips, brakes (front and rear) tires, seat cover, wheel bearing and air filter... My parts list is mainly replacing some wearable items, and to make sure it would be reliable. The bike would be used as a buddy bike, so I'd like to adjust the power to be more mellow than a full on MX bike, hence my search for a KDX.

What should I be looking for, what can I expect?

Any and all comments welcome.

[Julien D]

Sounds like you can expect to spend quite a bit of cash to get it going. The E series (89-94) KDX is a fantastic machine, very capable and very comfortable even for full day rides. The power delivery is arguably the best of any of the kdx200 engines. Some parts are becoming hard to get, such as power valve components and such. When checking it out, there's nothing KDX specific you need to look at aside from the function of the powervalves, which you would not be able to inspect without at least pulling the pipe to get a view through the exhaust outlet. At that age, the cylinder is probably going to need a replate, and the bottom end will be questionable as well. Check all the wheel / linkage / swingarm bearings, condition of the airfilter, etc. All the basic stuff you would look for on any used bike.

[sthoward]

How much money does he want for it?

[bultaco4ever]

I am doing exactly what you are doing...to a '93. It is missing most of the same stuff. I gave $400 for my bike raw. I'll probably spend about $800 to make it reliable and semi pretty. My bike ran when I bought it. I got lucky on the piston, rings and cylinder. Those are all perfect. The Kips valves are toast but you can get replacements. They are pretty simple, really. If you have to split the cases you'll spend more. I don't think that I have to.
Things I buy:
air cleaner
chain
tires
throttle cable
new jets
wheel bearings
shock bearings
fork seals and fork service(I farmed this job out)
brake parts
hand grips
missing parts: radiator shrouds, fork guards,

You'll probably do this on any brand that you get. KDX is a great resto project IMO...good parts availability. Easier than most.

[Keystone]

If it's got the blue anodized USD forks it's either a '93 or '94 E-series. Just my opinion, but I think the blue USD '93-'94 are the best woods forks KDX 200 ever came with. I've heard they are not great for fast stuff, but I've ridden them fast and never had a problem although,I'm not what you'd call a very fast rider. I don't know why they ever went back to those low underhang forks on the H-series, probably to save money.

Engines on these KDX200's are just fun. Plush bike, I sometimes ride through the rough rocky **** sitting down.
You get this bike up and running sweet, the KTM may be jealous.

[Friedom]

Hey OP. I'm restoring a 92 200. Got it for 200 in awful shape (including a seized engine).
I'm about 1500 into rebuilding/engine work, tires, steel valves, seals, parts, plugs, silencer, filter, chain, and general service and replacement parts.
Mind you, 1000 of that is on hiring a shop to plate, port, polish and rebuild the engine.
About to drop another few hundred on suspension and frame cleanup/paint.
Thought it would be a useful reference point for you.

Joy to the world!

[eprovenzano]

Well the bike sold... but I'm hot onto another one... this one is a 91 basket case... The engine was pulled as it was down on compression.. Owner says the bottom end is fine, just needs top end. After I pressed him a bit he said the jug needs replaced... In another message he said it needs a cylinder head... Not knowing until I see it, I think it needs a head. Based on some quick research, I found the cylinders are not plentiful, and they're not cheap. Repairs / replating will cost more then I plan on spending for the project... If it's the head... I can handle that.. It has a new clutch basket, new clutch plates, chain, brakes rebuilt forks, and new tires...

Again it's a complete basket case... It's been stripped down to the frame, so I'll need to make sure all the little pieces are there. So far I'm assuming I'll need a cylinder head replacement, new piston & rings and a gasket set. Based on the few pics I've seen I'll also be replacing the grips and seat cover. I'll take my calipers with me when I look at the bike to get the measurement of the cylinder bore. One good thing about picking up a basket case project, when you reassemble the bike, you have the opportunity to look at every nut / bolt / bearing and can make sure it will be a safe reliable bike

[eprovenzano]

I went to look at the bike..err project... The issue with the engine is a broken left KIPS valve... based on my research I'm sure that doesn't surprise anyone. The plastic is ruff, but its all there except the exhaust pipe... The bottom end was tight, new clutch and clutch plates. Rims are straight, tires decent. Even the piston and rigs are in reusable condition.

Current asking price is $250. I need to do a little more research before I make an offer.

[eprovenzano]

I've not been in a hurry, but the seller is very motivated. He said make an offer, so I did... I made an offer of $150 and he accepted. So I'll be joining the ranks of the KDX owners club in a few days when I pick up my new to me 1991 KDX 200 basket case

Based on my research on what the bike needs... I know the left KIPS valve is broken. I'm trying to decide whether I just replace the Left valve, or go with the complete steel replacement. She'll get a new top end gaskets, piston and rings. The frame will be repainted, and all moving parts will receive a nice coating of grease. I'll start putting together a list of required, necessary needed, and of course a wish list

I'll post pics once I pick up the bike

[6 Riders]

I've not been in a hurry, but the seller is very motivated. He said make an offer, so I did... I made an offer of $150 and he accepted. So I'll be joining the ranks of the KDX owners club in a few days when I pick up my new to me 1991 KDX 200 basket case

Based on my research on what the bike needs... I know the left KIPS valve is broken. I'm trying to decide whether I just replace the Left valve, or go with the complete steel replacement. She'll get a new top end gaskets, piston and rings. The frame will be repainted, and all moving parts will receive a nice coating of grease. I'll start putting together a list of required, necessary needed, and of course a wish list

I'll post pics once I pick up the bike

Crap, for $150 you can E-bay the wheels, make all your money back and still have a whole bike to sell......Great buy, no matter the condition or the intended use!

[eprovenzano]

Thanks 6 Riders, my intention are to rebuild the bike. I like the idea of having a buddy bike. I'm not a MX'er (too damn old to be flying through the air) but I do enjoy the challenge of single track... I didn't want to deal with the suspension and weight issues of an older non MX 4 strokes... nor the issues and cost of a "modern" MX stroker. Besides I'm just not a 4 stroke guy... I grew up riding smokers through the woods... and that's where I'll stay. Since it's going to be a buddy bike, I didn't want a fire breathing MX monster that I have to tame to ride single track... Like I said earlier, Yes I like orange... I was searching for a KTM 200 but I couldn't find anything in my price range (cheap), so I then researched the KDX line. I chose the KDX for its forgiving power characteristics, plus it's inexpensive to run.

As far as the bike, Since its a buddy bike, it will not get ridden every day, nor as often as my KTM 380.. (sorry there's nothing like a bike bore single track machine) One nice thing about a basket case, is you can access various part that you normally can't get too... I can say for sure there's no play in the crank rod, or crank bearings, the bottom end is tight. So all I need to do is to rebuild the top end. I need to decide if a replacement LH valve and collar is sufficient, or if I should just purchase the steel replacement and be done with it. I am kind if a maint nut, so this is a tough call. It will get a new piston and rings, (I'd be crazy not to replace the piston / rings since the top end is off the motor), new gaskets, etc. It needs an exhaust, I'm trying to decide to pony up for the Knarly or go stock. Of course it will need a few cosmetic things... but doesn't all $150 bikes

When I get my grubby hands on the bike I'll be in a better position to truly assess its needs.

[eprovenzano]

Here's a pic of the cylinder in which you can see the broken LH valve.



I'm glad I researched the potential issues with this bike on this site. It gave me the insight and knowledge to know what to look for and what I could expect when doing the repairs. Rebuilding a smoker is not too difficult, especially armed with the knowledge of what to look for, and how much $$$ is needed to bring it back to its former glory.

[eprovenzano]

I pulled the rest of the pics off the add... since these were taken, the PO put has remounted the entire front end, the rear swingarm and tire, as well as the wiring harness. The bike aslo has has a new clutch basket and clutch plates, new brakes, new chain newer tires, and the front forks have been rebuilt. Like I said, it's a basket case...

[Bitteeinit]

Interesting project!

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[eprovenzano]

I've been searching the ol "Interwebs" for LH exhaust valves... supply is limited and if available very pricey... I think I'm just going to pony up and get the complete set from BDK Racing http://bdkraceeng.co.uk/tc/products.php ... 12c8e6ea4b. If my calculations are correct, accounting for the shipping and currency exchange, the complete set would be $100 more than if I purchased just one NOS valve and collar... I'd really be too cheap and stupid to not just replace all the exhaust valves.

I ran a quick list of parts, exhaust, (stock) exhaust valves, complete top end, grips paint, etc. and my parts bill should be $400, plus the purchase price of $150 I'll be in this project for $550. Not to bad... at that price point I can flip it, or keep it as a buddy bike. Either way, it's not enough to break the bank, and or piss off boss (ie, the little woman).

[eprovenzano]

I picked the NTM (new to me) 91 KDX 200E last night... The PO had the bike partially assembled back into a rolling chassis. I planned on using my hitch carrier to bring her home, but the hitch is rusted / frozen to my jeep's Grand Cherokee's receiver, so plan B was put into place... We pulled the forks, and back tire and put the frame in in back of my Jeep, followed by the forks with the front wheel still attached, next was the back wheel, and then boxes and crates of parts. I think I got lucky as the PO is a diesel mechanic. When he dismantled the bike, he maticiously bagged and tagged all parts, screws, nuts / bolts etc. The frame and most parts were pressure washed after he originally dismantled the bike. so I get to work with a clean bike...

Mechanically I'm sure I can make sure she will be a reliable bike... cosmetically... she's going to be a challenge. All the plastic has been painted multiple times... its currently black, and looks terrible. Since I'm a cheap ass... I foresee a lot of sanding, primer, sanding, primer and painting, sanding, painting, and finally clear coat... in my future...

Here's a few pics of the basket case currently sitting in back of my Jeep





As I said before I do ride orange... here's my baby... an 01 KTM 380

[eprovenzano]

I did an inventory of the parts, pieces... Other then the exhaust (which I already knew) the only other missing items are the air filter and radiator shrouds....


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