1991 KDX 200 basket case.

Post by **Keystone** » 11:49 am Jan 24 2016

Great deal on that KDX. I love rebuilding them, especially when you buy used and aren't sure what's inside.
Wellsburg, I'm about an hour and a half east of you.

Post by **Julien D** » 12:42 pm Jan 24 2016

Looks like you've got a rare 91 white and blue KDX, with the original white plastics intact. SCORE.

eprovenzano · Post by **eprovenzano** » 01:01 pm Jan 24 2016

The front fender is silver under the black so it's getting another coating... I'm hoping its white under the silver. The rear fender is steel so it's not OEM... Lol.
Little by little it will come together.

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Friedom · Post by **Friedom** » 11:23 pm Jan 24 2016

I'm using baking soda blasting to clean the spray paint off of my DX plastics. It's like a magic eraser on graffiti.
Leaves you looking like a snowman, though.
Joy to the world!

eprovenzano · Post by **eprovenzano** » 10:03 am Jan 26 2016

While the Easy Off oven cleaner is working removing the paint, it's just taking too long... there's several layers of paint that I need to work through. Plus where the plastic has deep scratches or a slight crack, I'm struggling to get the black paint off... One the front fender, I did find the original white plastic under a layer of silver paint. I'm going to try a different paint stripper. I've been doing some research on different products, and will post results. I foresee a lot of sanding in my future to bring back the original luster to the plastic. It's amazing when you look at the back side of the headlight bezel... the white is so clean, so pristine... I'm not sure If I can get the plastics back to that quality, but I'm going to try...

david · Post by **david** » 11:34 am Jan 26 2016

You can also wet sand and polish plastic just like paint. Lots of work, so I would suggest a 3" mini buffer/polisher.

Friedom · Post by **Friedom** » 11:35 am Jan 26 2016

A heat gun can do wonders on faded plastic. You can use it to just barely melt the outer most layer and get that shine back.
Now over time the material composition of the plastic will wear and change, but this can help bring some life back into it.

Joy to the world!

eprovenzano · Post by **eprovenzano** » 04:42 pm Feb 03 2016

Well I ordered the KIPS valves from Brock at BDK Racing on January 19th. He had them to the post office the next day... I also received an email with the package number. I checked the status of my package... it shows "they have my package"...

Well that was 2 weeks ago... and the tracking status still shows the same message, "they have my package". No activity has been posted since the 1st post.

Now this is not a blemish on Brock... he's been great, he even tried to track down the package for me. But somewhere in postal hell lies my KIPS valves.

I've put off spending money on additional parts until on the KDX until this situation is resolved.

According to the UK postal service, I cannot file a claim until February 23. The item is not deemed lost until it has not arrived at it destination 25 working days after the due date of delivery. Plus the claim must be made by the sending party... Brock is more than willing to file the claim at the proper time, but in the meantime... THIS SUCKS!!!!

All I can hope is the package arrives... someday...

MotoArts · Post by **MotoArts** » 11:10 pm Feb 07 2016

I inquired about that bike too. The asking price was outrageous IMO, but you scored it right!

My interest was in the white/blue edition too.
I would advise NOT using any abrasives, scraping or blasting!! I've used basic orange citrus stripper available in many hardware stores with good success on rattle can paints. It will require several applications, since it is not the most aggressive chemical. Leave it work for several hours, scrape with a plastic body putty spreader or similar flexible tool, you'll save aggravation later on in the process.
Only use Aircraft stripper as a last resort!

Be patient. You will have a unique ride when done.

Post by **Tyl3r** » 11:48 pm Feb 07 2016

If the oven cleaner gets most of the paint off, I would just sand the rest out. Start with some 600 or so, and go up from there to 1500 or 2000 at the end. Then put some polish on a buffing wheel and shine them up. I did that with awesome results on my 400ex a couple years ago. Its about time for it again come to speak of it lol I remember watching a youtube video on it before i did it.

eprovenzano · Post by **eprovenzano** » 08:55 am Feb 08 2016

MotoArts wrote:I inquired about that bike too. The asking price was outrageous IMO, but you scored it right!

My interest was in the white/blue edition too.
I would advise NOT using any abrasives, scraping or blasting!! I've used basic orange citrus stripper available in many hardware stores with good success on rattle can paints. It will require several applications, since it is not the most aggressive chemical. Leave it work for several hours, scrape with a plastic body putty spreader or similar flexible tool, you'll save aggravation later on in the process.
Only use Aircraft stripper as a last resort!

Be patient. You will have a unique ride when done.

Thanks MotoArts... While the easyoff did a good job, I have switched over to the orange citrus stripper. At this point I have the front mask done, the exterior of the side number plates, the radiator shrouds, the front fender, and most of the tank. I'll still be stripping paint for a while, then the sanding can begin... That's always fun...

I will need to do some repair to one of the shrouds, a piece is the center has broken off... I think I can repair it...

This project has somewhat stalled... I'm still waiting to resolve the lost KIPS valves.. I hate to spend money on additional parts until the KIPS issue has been resolved. At this point I believe my valves are lost in Postal Hell... I'll have to to have Brock put in a claim as soon as the required time has elapsed... I have to wait until the 24th before a claim can be entered... So in the interim, I've decided to remove the old antiquated cabinets in my garage / workshop and build a custom set. The new layout will have twice the storage capacity, and will fit the place much better.... Yep it's the off season, and I like to keep busy... so this will keep me busy, while making my "work" area much better and more functional.

eprovenzano · Post by **eprovenzano** » 08:53 pm Feb 16 2016

I came home from work to find a note from the post office... My long lost KIPS VALVES are at my local post office... My wife has graciously agreed to pick them up for me tomorrow. It looks like it time to restart this project . I need to order a new top end kit and finish the restoration of the plastics. I 'll probably repaint the frame and then reassembly can begin.

WOOT WOOT

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Friedom · Post by **Friedom** » 09:00 pm Feb 16 2016

Nice! I'm waiting on mine to arrive (no idea when).

Then I can tear it all apart again like I just did. I already have a leftover top end gasket set that came with my wiseco piston for the other bike.

Fun Wheel Drive

eprovenzano · Post by **eprovenzano** » 08:43 am Feb 18 2016

The long lost KIPS valves from BDK Racing has arrived... I must say that the quality of the valves was worth the wait and frustration.

Anyone thinking about getting a set... do it... it's well worth the time and money.

jaywylie · Post by **jaywylie** » 08:42 am Feb 19 2016

Excellent write up! I am going to stay tuned. Keep up the awesome work and the pics!

eprovenzano · Post by **eprovenzano** » 11:01 am Mar 01 2016

The remodel of the man cave / garage is almost complete. I removed the previous cabinetry and used inexpensive kitchen cabinets to build a 12ft work area, with room to keep the air compressor tucked out of the way. Next I need to get everything put away and get back to the rebirth of the KDX

Parts that I recently ordered, include a stock exhaust ( I didn't get one with the bike), new Weisco top end kit, and an air filter. The man cave / garage rehab will be finished soon just in time for the new parts to arrive and to get the KDX project back on track.

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MotoArts · Post by **MotoArts** » 07:03 pm Mar 01 2016

Nice cave!

eprovenzano · Post by **eprovenzano** » 08:51 am Mar 03 2016

I have a little confession... When I 1st disassembled the KIPS I thought I carefully bagged and tagged everything. I was looking at the power valve (KIPS) parts last night. I was comparing BDK Racing's valves against the OEM (excellent quality BTW), when I noticed I was missing the little circlip spacer for the center valve... Now as you may know I've been remodeling the man cave / garage, so a lot of cleaning has been done, things moved, and some stuff just tossed... At 1st I thought it was no big deal, I'll just order a new one, what can it cost a few $$$... I jump on the internet, and see "Out of stock" hmmm, I don't believe it's being made anymore, so It may be difficult to impossible to find a replacement.

So my son and I go back to the garage, and meticulously go through everything... He was checking everything we've sweep up thinking it was lost in a cleanup, while I slowly remove everything from the workbench. When I was just about to give up I spy the little circlip spacer sitting under some misc stuff... It was close to where I disassembled the KIPS valves... OH HAPPY DAY!!!

I would have bet I sweep it up in one of the cleaning sessions... I was beginning to think I'd have to fabricate a replacement...

Next on the list is to install the new and improved BDK Racing KIPS valves... I'll be following the post by Freedom http://www.kdxrider.net/forums/viewtopi ... 15&t=15320... thanks for posting detailed pics. I understood the timing of the left and right valve, but was unsure of the center valve. Freedom's post helps to clear that up. My parts (exhaust, new Weisco top end kit, and an air filter) should begin arriving this weekend and / or early next week. Tonight I hope to put the rolling chasis and boxes of parts back into the workshop so the the reconstruction process can begin.

Friedom · Post by **Friedom** » 09:24 am Mar 03 2016

Glad you found your part! I've got a set of BDK valves ready to install in the 93, though it's starting to look like it might need crank seals(doh!). Anyhow, nice link, but that's the work of Keystone, not me.
Cheers!

Fun Wheel Drive

eprovenzano · Post by **eprovenzano** » 06:50 am Mar 04 2016

Thanks Friedom. Keystone I want to sent a shout out for a thank you for your post.

I began cleaning the cylinder for the installation of the KIPS valves. Per Brock's BDK Racing) instructions "make sure to clean the cylinder especially the bottom holes where the valves sit before reassembly". I used carb cleaner, there's still a little more to do but it's coming along. I also cleaned the carb.. It was clean, but it can never be too clean... One tip.. Please guys do not over tighten the pilot and main jets... They are brass and do not need torqued to 100 foot lbs. I really had to work to get mine out.

Parts are starting to arrive. The replacement exhaust is here. Just needs cleaned up and a coat of high temp paint.

One question... There's a spot for 0-rings on the exhaust. Anybody have a cheap alternative to the OEM O-rings?

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