KDXRIDER.NET

Hi everyone,

I decided last year I wanted to get into dirt riding and this year picked up a 2001 KDX200. I'm going to be taking my first woods ride this weekend out at the Red Top Trail in McGrath, Minnesota with a friend of mine who picked up a 2000 YZ125.
The KDX is equipped with an FMF Gnarly pipe, but I'm not sure if it's the right one as the lower muffler damper/hanger doesnt' fit without modification, and the kickstart lever rests gently against the pipe when stowed.
(Both pictures are before I cleaned it up a bit.)

Welcome to kdxrider.net.

With a name like comrade, thank you for not being a Russian spammer. I was hesitant to activate your account.

Congratulations on the KDX! See if the kickstarter knuckle is worn, allowing the lever to lean over.

Be sure you have all the mounting pieces for the pipe, and the pipe mounting tabs are not bent out of the correct alignment.

https://www.partzilla.com/catalog/kawas ... /muffler-s

Welcome to the forums and congrats on the bike. Now get out and ride that thing!

The first ride out at the Red Top Trail was successful and aside from one of the rear brake pads falling out the bike did great. I did take a look at the header pipe, and it looks like the upper hanger tab might be bent. I think if I straighten it out, it will help the other tab line up. The pick pedal mechanism doesn't seem to have any play in it, maybe the lever self is a little bent.

Good to hear your first ride went well. If you remove the nut, pull the Kickstarter and rotate it one spline counter clockwise that should get it sitting right. Use blue loctite on the nut when you put it back on.

John_S wrote: 10:36 am Jun 02 2019 Good to hear your first ride went well. If you remove the nut, pull the Kickstarter and rotate it one spline counter clockwise that should get it sitting right. Use blue loctite on the nut when you put it back on.

Yeah, just looked at mine. The kickstarter is definitely rotated clockwise a spline or two (or more???).

One thing I forgot to mention, the front brake line holder tab on the left fork is broken off, it's currently held on by a single zip tie. Is there any good way to fix the tab? Or should I just apply more zip ties?
this is somehow the best picture I have of that side of the bike right now.

TIG weld it up
grind it down
sand it, drill it, deburr, etc.

Can you post a better pic?

Looks like its in great condition!! Good luck!

TwistedRoot wrote: 07:54 pm Jun 07 2019 Looks like its in great condition!! Good luck!

The tail section is a bit twisted, but it's in great shape mechanically.

KDXGarage wrote: 10:39 pm Jun 06 2019 TIG weld it up
grind it down
sand it, drill it, deburr, etc.

Can you post a better pic?

I swear that first picture looked clearer when I took it, but you get the idea. I think there is plenty of the bracket left on the fork leg to have no problem TIG-ing it back on. I also just noticed that the clamp for the fork boot is crocked, probably jostled by the bracket going by.

I would see if someone could TIG it back on.

There's a technical school not too far away that I'm thinking of dropping a line to, maybe weasel my way into a free weld. There is also a custom welding shop nearby I might try out.

Try liquid metal or some apoxy, clean the areas up with brake cleaner first then apply & let it set over night ....if it doesn't work & you have to weld it then be careful that the heat from the torch doesn't damage your fork seal !