2000 KDX 200

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September 7, 2010 at 12:20am PST

I am the original owner of a 2000 Kawasaki KDX 200. I rode the bike for roughly 5 years, probably no more than 300 miles total. It has been sitting since 2006. I pulled it out a few days ago, turned the 5 year old fuel on, choke and kicked about 30 times. It started and ran like it did 5 years ago, fat with a blobbering top end. The plan is to tear down the entire bike minus the forks, rear shock and bottom end. From what I can tell, the internals are pristine. I sent the jug and head off to Eric Gorr for the big bore 225 kit with the works (polishing and porting). I can't wait to see his work!

I will be posting my progress here, as an informational source and historical documentation.

My son Roman and my 2000 KDX 200 after 5-6 years of sitting.

I removed just about everything, leaving the brakes, front end, rear end.



Top end was sent to Eric Gorr for 225 big bore kit and porting/polishing work.

Engine removed

Roman is really excited about the rebuild!

Safety Roman

Electrical and Intake parts (fuel can is for the mower)

I've ordered the following stock replacement parts:

  • (Qty: 1) 11004-1298 - GASKET-HEAD
  • (Qty: 1) 11009-1941 - GASKET,REED VALVE
  • (Qty: 1) 11009-1996 - GASKET,CLUTCH COVER
  • (Qty: 1) 11060-1340 - GASKET,FUEL TANK CAP
  • (Qty: 2) 11060-1628 - GASKET,RESONATOR
  • (Qty: 1) 11060-1629 - GASKET,RH,COVER
  • (Qty: 1) 11060-1659 - GASKET,CYLINDER BASE
  • (Qty: 1) 12053-1328 - GUIDE-CHAIN,DRIVE,FR
  • (Qty: 1) 13234-1101 - SHAFT-COMP,GOVERNOR
  • (Qty: 1) 13236-1260 - LEVER-COMP,GOVERNOR
  • (Qty: 2) 220AA0306 - SCREW-PAN-CROS
  • (Qty: 4) 220AA0610 - SCREW-PAN HEAD,6X10
  • (Qty: 1) 51049-1108 - CAP-TANK,FUEL
  • (Qty: 1) 92072-1229 - BAND,FUEL TANK
  • (Qty: 4) 92143-1156 - COLLAR
  • (Qty: 2) 92150-1888 - BOLT,SOCKET,4X8

And planning on ordering the following aftermarket parts:

I am definitely removing the taillight and possibly using a blank front plate with no light.

September 7, 2010 at 9:31am PST

It's decided. I'm also going to have the frame and swing-arm powder coated by All Bay Powder Coatings in Fremont, CA.

September 7, 2010 at 10:28pm PST

I've torn it down as much as possible. I now need a press to push out the stem and swingarm bearings.

I'm going to pick one of these up tomorrow.

Removed swingarm

Ready to be blasted and coated tomorrow

Frame, swingarm and stand

More parts! What did I get myself into?

September 8, 2010 at 7:23pm PST

Just picked up a 12 ton hydraulic press from Harbor Freight for $129.00


Put it together


Bottom bearing was stuck. I didn't want to bang it with a hammer.

Lined it up

Bottom shot

Bottom of stem

Got it out. I'll need to push the stem out of the clamp later.

Stem removed

Races are still in there. Not too sure how I'm going to get them out.

Old stem races

Finally! The frame is ready to be dropped off for blasting and powder coating.

Bare frame

That sure took a long time! I guess I didn't take any pictures of the swingarm. I removed 6 bearings from the swingarm as well.

I dropped off the frame, swingarm and kickstand for powder coating. It'll be ready in 4 days!

September 9, 2010 at 3:30pm PST

I bit the bullet and added the following stock replacement parts

  • (Qty: 1) 11012-1762 - CAP,STEERING STEM
  • (Qty: 2) 92122-1153 - ROLLER,CHAIN GUIDE
  • (Qty: 4) 11012-1259 - CAP,SWING ARM
  • (Qty: 4) 92046-1118 - BEARING-NEEDLE,TA2015
  • (Qty: 1) 42036-1245 - SLEEVE,15X22X57
  • (Qty: 2) 92004-1132 - STUD
  • (Qty: 2) 92004-1142 - STUD,8X28.5
  • (Qty: 8) 92004-1253 - STUD, 8X32
  • (Qty: 12) 92015-1406 - NUT,8MM
  • (Qty: 2) 92046-1216 - BEARING-NEEDLE,22BM28
  • (Qty: 1) 92047-017 - BEARING,STEERING STEM
  • (Qty: 2) 92049-1402 - SEAL-OIL,MHA22 28 5.7
  • (Qty: 6) 92071-056 - GROMMET
  • (Qty: 1) 92116-1069 - BEARING-ROLLER

September 15, 2010 at 11:29am PST

My 2001 KX500 forks arrived!

Just arrived


Unpackaged forks

Old 2000 KDX200 forks next to my 'new' 2001 KX500 forks.

Both sets

September 16, 2010 at 3:04pm PST

Just picked up the frame, swingarm and kickstand

All wrapped up.

Amazing coating job by All Bay Powder Coating! Thanks Lupe!


Another frame shot




Another swingarm shot




September 22, 2010 at 2:45pm PST

OEM parts arrived!


A little intimidating... Some of these bags have 20+ parts in them.


September 25, 2010 at 7:14pm PST

Pressing in the new bearings.

Swingarm bearings

.33 inch depth

Swingarm bearings depth

.33 in depth close-up (bearing depth for front swingarm bearings)

Swingarm bearings depth close-up

Front bearings done


Rear shock bearing--what a pain!

Rear shock bearing

.19 inch depth

Rear shock bearing depth

.19 inch depth close-up (bearing depth for lower swingarm bearings)

Rear shock bearing depth close-up

All bearings without seals installed

All bearings without seals

All bearings and seals installed (another shot)

All bearings and seals

All bearings and seals installed (before packing)

Before packing

All bearings and seals installed (after packing)

After packing

Old stem race, major PITA, took about an hour to bang out.

Old stem race

New stem races installed.

New stem races

Old stem bearing

Old stem bearing

"Specialty" tool.

The "special" tool.

"Specialty" tool/pipe.

The "special" tool.

New stem bearing on 2001 KX 500 stem

New stem bearing

October 1, 2010 at 6:09pm PST

Cylinder and head back from Eric Gorr

I was looking forward to seeing Eric's work. I was in for an extremely unpleasant surprise. This is the worst engine work I've ever seen. My high school machine shop produced 10 times higher quality work.

Cylinder deck pitting! He didn't even resurface the deck! The cylinder I sent him was pristine.

Eric Gorr's work

Every single thread has been helicolied! On-top of that, done incorrectly. WTF happened to my cylinder!

Eric Gorr's work

I paid for a polish and port job. It looks like he didn't touch it.

Eric Gorr's work

Wrong size washers...

Eric Gorr's work

Stripped and destroyed plugs.

Eric Gorr's work


Eric Gorr's work

October 9, 2010 at 11:23am PST

Aftermarket parts: (SKU numbers are from Motorcycle-Superstore)

  • Pirelli - MT 16 All Terrain MX Rear Tire: Color: --, Size: 110/100-18 (SKU: #43347)
  • Pirelli - MT 16 All Terrain MX Front Tire: Color: --, Size: 80/100-21 (SKU: #43297)
  • IRC - Rim Strips: Color: --, Size: 21" (SKU: #40851)
  • IRC - Rim Strips: Color: --, Size: 18" (SKU: #40849)
  • Michelin - Heavy-Duty Inner Tube: Color: --, Size: 18" Type A (SKU: #278113)
  • Michelin - Heavy-Duty Inner Tube: Color: --, Size: 21" Type A (SKU: #278121)
  • Renthal - 520 Off-Road Rear Sprocket: Color: Black, Size: 50 (SKU: #59951)
  • Renthal - 520 Off-Road Front Countershaft Sprocket: Color: Steel, Size: 13 (SKU: #58744)
  • Renthal - 520 R1 Works Chain: Color: Gold, Size: 114 (SKU: #44989)
  • Works Connection - Skid Plate: Color: Aluminum, Size: -- (SKU: #130829)
  • EBC - X-Series Carbon Graphite Front Brake Pads: Color: --, Size: -- (SKU: #87076)
  • EBC - X-Series Carbon Graphite Rear Brake Pads: Color: --, Size: -- (SKU: #171825)
  • IMS - Folding Shift Lever: Color: --, Size: -- (SKU: #133864)
  • Acerbis - Front Fender: Color: Black, Size: -- (SKU: #134731)
  • Acerbis - Lower Fork Covers: Color: Black, Size: Pair (SKU: #137442)
  • Acerbis - Front Number Plate: Color: White, Size: -- (SKU: #134952)
  • Pro Taper - Rubber Mount Kit: Color: --, Size: -- (SKU: #130153)
  • Moose Racing - Competition Lever Set: Color: Black, Size: -- (SKU: #257209)
  • Pro Taper - EVO Handlebar: Color: Black, Size: Carmichael (SKU: #157491)
  • Moto Tassinari - VForce3 Valve System: Color: --, Size: -- (SKU: #197954)
  • Fly Racing - Pro-Pak Silencer Repack Kit: Color: --, Size: -- (SKU: #40022)

Aftermarket parts arrived today! Roman is inspecting quality.

Aftermarket parts arrived today.

Parts laid out.


Roman checking tire size.

Roman checking tire size.

October 10, 2010 at 6:23pm PST

2001 KX500 fork clamps and tubes installed.

KX500 forks.

Fork tube depth.

KX500 tube depth.

Front wheel mounted.

KX500 wheel mounted.

Engine cleaning, before


Engine cleaning, after.


New front sprocket. (Renthal 520 13-tooth steel)

New front sprocket.

Engine mounted.

Engine mounted.

Rear wheel mounted.

Rear wheel mounted.

Rear aluminium sprocket. (Renthal 520 50-tooth aluminium)

Rear sprocket.

New, clean chain guide and guards.

New guards and guides.

New Pro Taper EVO Carmichael bars.

New Carmichael bend bars.

Bars and new clamps mounted.

Bars and clamps.

Bar clamps.

Bar clamps.

Bar clamps-closeup.

Bar clamps-closeup.

Done for today.

Done for today.

October 13, 2010 at 4:19pm PST

I decided to paint the top-end.


Before paint

A good tape job

All taped up

Hanging in the backyard, first coast of paint

First coat

After paint, three coats


After paint, three coats


October 16, 2010 at 7:23pm PST

Ok, a few friends talked me into painting the bottom-end as well.


Before paint


After paint

Crap. I decided to take a look at the stator to see if I saw any oil, possibly indicating a leaky seal. This is what I found.

I dropped the bike in salty water about 10 years ago. Never looked inside.

Rusted flywheel

The crank is still pristine, which means the seal should be good. The water must have gotten in from the cover side.

Showing clean crank and rusted flywheel

Installed new fork seal saver skins

Seal savers

Scotts sanoprene KX500 bar cones.

Bar cones

Acerbis front black fender.

New black fender

Roman working on the clutch while I insert the main swingarm bolt.

The Team

October 21, 2010 at 10:32pm PST

I finally got the flywheel off and cleaned things up.









October 23, 2010 at 4:25pm PST

Cleaned up the flywheel and stator. Started putting the motor back together.


Killing the cancer

Destroyed stator bolts

Old stator bolts

All cleaned up and ready for paint

Ready for paint

Stator installed

Stator installed

Flywheel painted

Flywheel painted

A little heat


Installed, torqued and loctite

All done

Cleaned covers installed

Cleaned covers

Kips alignment-RH

RH Kips Valve

Kips alignment-LH

LH Kips Valve

Kips alignment-RH-open

RH Kips Valve-open

Kips alignment-LH-open

LH Kips Valve-open

Old 200cc piston next to new 225cc piston


Ring gap check .010

Ring gap check .010

Cylinder bolted on

Cylinder bolted on

New head studs installed

New head studs

Motor ready for installation in chassis

All done!

October 27, 2010 at 9:58am PST

I wanted wider footpegs. I picked up a pair of these.

D2Moto Footpegs $9.99

Wider pegs

October 24, 2010 at 12:16pm PST

Exhaust cleaning begins

Dirty silencer

First time cleaning the expansion chamber

Dirty expansion chamber

As good as we can do with a cheap polisher attatchment for my drill

Cleaned up

Engine installed

Done for today

October 29, 2010 at 12:58am PST

We were able to install the airbox/boot, chain, electrical, clutch, front/rear brakes, rear fender, mud flap and shifter.

Also,.. When I was replacing the govenor lever that I broke off inside the motor during dissassembly, I apparently missed the shift lever return spring. I had to tear down that side of the motor again to fix it. That added another 30 minutes to the night.

I got a whole crew helping me out tonight.

Fitting and cutting the new chain

Airbox/boot and reeds

Getting there....

October 31, 2010 at 6:50pm PST

I was able to finish the controls, exhaust and carburator (35 pilot 150 main).

Happy Halloween!

Happy Halloween!

Packed the silencer and installed the exhaust system

Exchaust installed

Almost finished!

Almost finished!

Almost finished!--another shot

Almost finished! other side

Just the fuel tank and rads left!

November 2, 2010 at 9:00pm PST

Old vs. new footpegs, took a lot of grinding to get them to fit correctly.

Stock vs. new D2moto foot pegs

The crew

Workin' hard

It runs! First start, finally!

November 3, 2010 at 5:39pm PST

Extra long front fender bolts through lower clamps for number plate

Extra long front fender bolts

Inside shot of long bolts with number plate on

Long bolts as dowels

Under front fender showing new long bolts

Under front fender

Notched number plate for brake line guide

Notched number plate

Number plate installed

Number plate done

New grips with a touch of green

New grips

I'm planning on replacing the green shrouds with black in the very near future. Time to ride this Friday!

Completely assembled

Completely assembled!

Completely assembled--another shot

Completely assembled!

Completely assembled--another shot

Completely assembled!