The World's worst 93 KDX Rebuild

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
SerpentZA
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Re: The World's worst 93 KDX Rebuild

Post by SerpentZA »

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Yay, new (probably crap) Swingarm bearings arrived! The ones on the bike are missing 40% of their rollers....

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Very cheap heavy steel sprockets! Maybe the momentum of these things will make it have a higher top speed [emoji14]

Tuesday I can continue!

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Churchill customs, Southern China's only custom bike shop:
http://www.churchillcustoms.com
SerpentZA
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Re: The World's worst 93 KDX Rebuild

Post by SerpentZA »

The Saga continues! ...
Today I found out where my original right KIPS valve went!
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Yes, it was rattling around in the exhaust in a few pieces...

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Not to be deterred, I decided to whipout the wire brush and sandpaper and see if I could salvage any of the remaining KIPS nonsense!

Surprise,Surprise! I managed to clean up the rod thingy and the front thingy! They're salvageable!

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they're worn and a bit damaged, but totally workable! They were just absolutely caked in carbon... idle valve and both kips valves are toast though...

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This head gasket is crap too, I may have to try and re-use it though as I can't find a replacement (I wonder why the PO hereafter referred to as POS) glued shut some of the water channels in the gasket?

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I got a new OEM piston in the mail today... not sure if it's okay, but it was the most expensive Chinese made one I could find... it's probably rubbish.. but better than what's in there...

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All set for next week! She may be a runner (minis kips valves)
Churchill customs, Southern China's only custom bike shop:
http://www.churchillcustoms.com
SerpentZA
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Joined: 07:34 am May 14 2015
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Location: Shenzhen, China
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Re: The World's worst 93 KDX Rebuild

Post by SerpentZA »

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Some home made gaskets traced and cut out! A fake Chinese NGK copy yay!

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Paid triple the going rate, but it's real... and these are the real score!

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Let's see if I can get her running next week!

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Churchill customs, Southern China's only custom bike shop:
http://www.churchillcustoms.com
Bitteeinit
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Re: The World's worst 93 KDX Rebuild

Post by Bitteeinit »

I would have sold you my unused kips set for less than the going! From Cambodia to China, even EMS would have been cheap.

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SerpentZA
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Joined: 07:34 am May 14 2015
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Location: Shenzhen, China
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Re: The World's worst 93 KDX Rebuild

Post by SerpentZA »

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trying to get all the spooge out since the new power valves don't move freely... there is some damage I hope to sand out with sandpaper...

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Churchill customs, Southern China's only custom bike shop:
http://www.churchillcustoms.com
nick.killick
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The World's worst 93 KDX Rebuild

Post by nick.killick »

How did you get on with this rebuild, managed to get her running again yet?
eprovenzano
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Location: Wellsburg, WV

Re: The World's worst 93 KDX Rebuild

Post by eprovenzano »

We dying for an update.


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
david
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Location: EAST TEXAS

Re: The World's worst 93 KDX Rebuild

Post by david »

He hasn't been on the forum since May 8th.
'81 KDX 175
'90 KDX 200
'07 Vulcan 2000 Classic LT (totaled 4/25/15)
'82 Honda GL500 (sold)
'96 ZXi 1100 JetSki
'98 STX 1100 JetSki
eprovenzano
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Location: Wellsburg, WV

Re: The World's worst 93 KDX Rebuild

Post by eprovenzano »

david wrote:He hasn't been on the forum since May 8th.
Damn... I hope all is well... :sad:
1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
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