New member - Ressurecting my old KDX200 E4!

[ToXic]

Hello everyone, I have a KDX200 E4 that I bought almost 20 years ago, and have no intention on selling [emoji14]



I have never used it much, but it has been very reliable and I loved it since day 1. It can go some years without running, but it will start soon after some gas, choke and a couple of kicks!
I really wanted to keep it as original as possible and the only upgrade I did was a Rental aluminum handlebar, a better air filter and reed valves. It never lets me down :)
Although it has been carefully "preserved", it has been waiting for my attention on some important items - suspension is too soft (rear shock is working on the spring), carb needs a cleaning, engine needs servicing (let's see what the compression check says), brakes need an overhaul, etc etc. Great thing with this bike, it still looks as good as when I bought it (low usage helps...).

I am counting on the forum member's expertise and also the ocasional "so how's the bike progressing" support to finally restore this bike to its initial (or better) glory! I will try to share my experience with the more technical stuff.

Cheers!

[Keystone]

Great looking bike, I love the E-Series. I've replaced two original stock pistons on E-Series and both had chipped, sharp looking edges around the skirt. KIPS valves needs looked at while the top end is off, internal gears are made of aluminum and sometimes shred the teeth. There is no way to check for wear on these teeth before failure without removing the top end. Don't rely on a compression check to identify those common issues. I love the soft suspension on my E-Series but I understand it's not good for fast riding. I can't imagine ever getting rid of mine either!

[jaywylie]

Awesome, that is a well-preserved bike you've got!

[david]

Welcome.

[Friedom]

beautiful! I've got an e4, though it's not nearly as clean or stock as yours. With any luck I'll take it to the vintage enduro track tomorrow and see how it (and I) does.

[KDXGarage]

Nice looking scooter.

If you are riding on spring, you need to give a serious inspection of the shock bore.

[ToXic]

Great looking bike, I love the E-Series. I've replaced two original stock pistons on E-Series and both had chipped, sharp looking edges around the skirt. KIPS valves needs looked at while the top end is off, internal gears are made of aluminum and sometimes shred the teeth. There is no way to check for wear on these teeth before failure without removing the top end. Don't rely on a compression check to identify those common issues. I love the soft suspension on my E-Series but I understand it's not good for fast riding. I can't imagine ever getting rid of mine either!

Hello Keystone, thanks for the heads up on the KIPS. I will surely remove the top end for general inspection, just to make sure all is OK... I have a set of piston rings in stock so they will be changed at least. While I have the top end removed, any other particular items to look out for?

When I said that the suspension is soft, I should have said that the rear is shot! Need to completely overhaul that shock (will follow some of the forum threads).. I also like the original plushiness :)

[ToXic]

beautiful! I've got an e4, though it's not nearly as clean or stock as yours. With any luck I'll take it to the vintage enduro track tomorrow and see how it (and I) does.

Good luck :)

[Friedom]

Great looking bike, I love the E-Series. I've replaced two original stock pistons on E-Series and both had chipped, sharp looking edges around the skirt. KIPS valves needs looked at while the top end is off, internal gears are made of aluminum and sometimes shred the teeth. There is no way to check for wear on these teeth before failure without removing the top end. Don't rely on a compression check to identify those common issues. I love the soft suspension on my E-Series but I understand it's not good for fast riding. I can't imagine ever getting rid of mine either!

Hello Keystone, thanks for the heads up on the KIPS. I will surely remove the top end for general inspection, just to make sure all is OK... I have a set of piston rings in stock so they will be changed at least. While I have the top end removed, any other particular items to look out for?

When I said that the suspension is soft, I should have said that the rear is shot! Need to completely overhaul that shock (will follow some of the forum threads).. I also like the original plushiness :)

There's a member on here selling a complete shock rebuild kit. He ships fast and his price is right. Just got mine, deciding on what shock weight to run and waiting for my other bike to be up before this one goes offline.

[KDXGarage]

I do sell the parts, but the bore is the main thing to check, and it should not be ridden like that.