My KDX200 E2 Rebuild Thread

gereonb · Post by **gereonb** » 02:41 pm Sep 26 2015

Here are the photos. She runs great, forgot to fill her up and had to walk back 4 miles yesterday though. Just mixed a fresh tank of 4 gallons 40:1, if she does't smoke too much I might lower that to 32:1 eventually.
I didn't rebuild the carb, I just put it on like I took it off. Will do that once I know what her quirks are.
Also need to put on the new UniTrack decals.

gereonb · Post by **gereonb** » 06:58 pm Sep 26 2015

So, been round the neighborhood a few times and so far I am keeping the shiny side up, keep in mind this is my first real motorbike.

1. How do you reset the Trip meter using that little knob on the side of the ODO, is it just pull out and wind back ?.

2. The power band is WAAAY scary, I replaced all the KIPS and it has Boysen radvalves and a Gold FMF. IT literally throws me off the back even in 6th. is it supposed to be that radical ?, I am leaning over the bars just to keep the front end down when it kicks in.

Gotanubike · Post by **Gotanubike** » 07:47 pm Sep 26 2015

They are pretty snotty huh

Especially with the fatty pipe,

The bike looks awesome, great job on the plastics. Someone else will have to chime in on the trip meter. Never had one on mine

gereonb · Post by **gereonb** » 10:58 pm Oct 03 2015

She is running sweet, keep riding her up and down the local roads to get used to the awesome top end.
Replaced the broken kill switch with a $2 Ebay part and had to replace the Gas Cap with a $25 oem part, both items had become brittle and cracked from the AZ sun.

The top screw on the right hand side of the tank (that holds on the plastics) is bad as you can see in the pics, the brass nut in the tank just turns and the screw is stuck in it, tiny bit of gas leaks out if the tank is full. For now I just sprayed some black All-Seal gunk on the nut/bolt to try and seal it up. I don't think there is any way to properly repair that issue apart from a tank swap.

I think my next step will be to get some proper MX riding gear, boots, helmet, some padded gloves (to hopefully soak up some of the handlebar vibration).

Post by **offshoretitan** » 05:48 am Oct 04 2015

Try a barsnake [www.barsnake.com] or shotgun pellets like #8 bird shot to fill the handlebars and eliminate the vibration; different gloves won't help much...

Great effort on the bike so far!

gereonb · Post by **gereonb** » 02:07 pm Oct 17 2015

I bought some Valeo Mechanics Anti-Vibe Gloves from Amazon and they are great, they soak up pretty much all the vibration, really a big improvement. Sounds silly but they look ok too.

Post by **offshoretitan** » 06:31 am Oct 19 2015

I wasn't aware they made those. Thanks for sharing - I'm going to order a pair.

bultaco4ever · Post by **bultaco4ever** » 11:32 am Oct 19 2015

Interesting stuff on the BDK replacement valves. How are they holding up? How long did it take to get them shipped? By the way...from your photos, it looks like your chain is 'too tight'. You'll wear your chain out prematurely.

gereonb · Post by **gereonb** » 11:00 am Oct 27 2015

Yep, the chain was a bit tight, eased it off one notch.
The BDK valves are great, they arrived very quickly 2 days to US from UK.

Issue are:
- Keep running out of gas, I forget to check and then the tank is too dark to see into, hmmm .. maybe strap a little led light to the bike.
- Midrange seems low on gas, when coming off the pipe from top-end the bike really stutters, I have to be really samooooth on the throttle in the midrange, low end is fine again. I read this could be the needle setting, I doubt it would be the air screw.
- Restarting when engine is warm is REALLY hard, takes 15 kicks sometimes and open throttle. When cold it starts on 1st kick.

jeffersonchristopher · Post by **jeffersonchristopher** » 06:44 pm Nov 07 2015

Fantastic thread buddy. Thanks!

gereonb · Post by **gereonb** » 12:52 pm Nov 30 2015

Thanksgiving was spent in Strawberry, AZ ripping up Forest Roads on my KDX200 with family.

I adjusted the gas needle in the carb as it was a bit Rich in the midrange of throttle. So I moved the clip up 2 notches, this brings the needle down more and closes off the hole, it certainly fixed my throttle response in the midrange.

Oh oh ... My gearbox oil is Milky white, I think the water pump seal has gone, although I cant see any missing water in the cooling system. Before doing anything I might drain and refill just to get an idea of how bad the situation is.
Any suggestions for a type/brand of gearbox Oil ?.

gereonb · Post by **gereonb** » 08:18 pm Feb 21 2016

Done about 500 Miles on her now since the rebuild and she runs like day 1.

I have been watching the gas and get about 20MPG, is that about right ?.

Gear oil still milky, and forks now really need new seals. Time to bring her back home and do a maintenance stop.

Friedom · Post by **Friedom** » 11:30 am Feb 22 2016

So what jets are you running now?
I'm getting ready to order water pump seals on our 93 too.

Fun Wheel Drive

david · Post by **david** » 01:24 pm Feb 22 2016

Is it milky after sitting for a day? If yes, then replace the water pump seals. If it clears up after sitting, it's just foam from being aerated and is normal.

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