KDXRIDER.NET

Hey guys, super glad to have found a forum like this, theres so much great info on here! No doubt I will be using this place a lot.

I have just recently got hold of my Dads Jap import 1990 KDX200SR, which isn't in great shape. Thought I'd give a go at fixing it up for use on the Byways around here. I'm pretty much a total novice to bike mechanics, apart from general maintenance and light tinkering on my DRZ. So it will be a long journey, but I'm keen to start (for now)

To be honest when I first got the bike I thought it was a standard model, I'm now realising sourcing SR parts is gonna be a real ball ache. I would love to know the best way to go about finding out which parts are specific to the SR and which standard 1989-1994 KDX parts can be used on both models, as I'm not totally sure on all the differences at the moment. Is worth me picking up a 1989-1994 KDX manual or not?

I'm gonna have a good look over the bike tomorrow and assess the problems, I'll post some pics then.

You'll be able to fit a lot of the fiddly bits from an E model, but as I recall the motors have some differences, as does the electrical system. Nothing really complicated though (and a fair bit easier than a DR-Z). Combing through microfiche parts listings will be the easiest way to track down interchangeability. There are also quite a few SR owners on here from Australia, though I don't know what the specific differences between a Japan Import model and an Australian one are. In the end, engineers are lazy, so lots of stuff should work across models, might involve a little mods now and then.

Regardless, congrats on the new project and welcome to the forums!

Hi. Welcome to kdxrider.net.

If you can post a frame number and an engine number, then I can look it up in the kawasaki Model Identification Guide. You may be able to find an online UK dealership parts diagram for your model, then compare it to the "dirt only" model.

Ok, thanks thats handy to know about mircofiche parts listing.

The frame number is DX200G-019888 but I'm not sure where you find the engine number.

I've attached a couple of pics but I'm now realising the rest are over 5mb

Here's the rest

The site has ran for over 16 years on donations or the owners dipping into their pockets to pay the bills for hosting and storage space. Sorry if 5 MB and a limit on number of pics in a post were not to your liking.

Thank you that will be very useful!

Sorry, wasn't meant to come off as a moan, I'm fine with the limit I just wasnt aware when taking the snaps.

LOL!! "A bit of a moan" is a new one on me. No problem at all. It ain't the latest and greatest, but there are no ads thankfully.

We are looking into some small changes to try to make things a touch more modern around here.

Really cool KDX by the way. Us USA people never had a street legal version, so we are keen to see pictures of the ones we never got.

aviato wrote: 04:23 pm Jan 15 2021 To be honest when I first got the bike I thought it was a standard model, I'm now realising sourcing SR parts is gonna be a real ball ache. I would love to know the best way to go about finding out which parts are specific to the SR and which standard 1989-1994 KDX parts can be used on both models, as I'm not totally sure on all the differences at the moment. Is worth me picking up a 1989-1994 KDX manual or not?

I'm gonna have a good look over the bike tomorrow and assess the problems, I'll post some pics then.

Mate I had the same experience. I did not know about SR model and spent a week trying to figure out what this fiddly bit of metal under the carb did as it was missing in all diagrams. Turns out it was the oil pump.

Yours looks heaps nice ,good luck with it. It is a really good bike, best bike I have ever had. I got my oil pump working well, and it makes life so easy and no goo or fouled plugs. Clear oil lines for peace of mind.
I did a shonky rebuild job on mine, it was the first time I have seen inside a crank case, first time bashing out swing arm and stem bearings, first time lacing a wheel. It was not as hard as I thought ut woukd be because of this forums search function.

The carbie is different so a carb rebuild kit wont work if you order e model. I found ou hard way. Also carb holder is different, but sikaflex 227 autosealant works if your carb holder crusty.

Most other parts seem to be the same. I ordered gasket kit, it worked, same with bearings.

If you are planning to open it up, I would get the service manual anyway because it has everything except for the oil pump. If you get around to cleaning powervalves, be aware that one of the threads is reversed. Dont muck that up like i did!

Cheers for the heads up mate, the bike is in much better shape than I first thought. For the most part things are in good condition, the exhaust system will clean up nicely and the carb is like new inside, looks like its never been apart!

Problems I've ran into so far are:

Tank is heavily rusted inside
Air box needs a good clean out and reline
Engine oil bleed bolt is stripped
Bolts that hold the fork protectors on are rounded
Seals are gone on the front brake

Haven't inspected the oil pump yet, that will be next

Good to know about the gaskets and bearings. I'm not planning on opening it up quite yet, I wanna see how she runs first

Does your model have the USD forks?

Wondering if anyone has found alternative protectors, as the originals feel like they are made of cassette tape plastic and would probably shatter at the thought of a drop lol

Mine had engine drain bolt stripped and jbwelded shut when I got mine. Fixed with a helicoil.

I got klx usd forks on mine which have flimsy universal covers on them. But I dont ride my bike hard and potter around rather gently and so far they have not fallen off but I think they are worse than stock.

One more thing.
My carb holder was so dry and crusty that once I got an air leak so sudden that the bike got stuck wide open would not shut off which was an interesting experience. I would take a look at that too.
I tried gasket sealer which failed. Sikaflex 227 autosealant made it nice and airtight.