2000 KDX 200
- 1 September 7, 2010 at 12:20am PST
- 2 September 7, 2010 at 9:31am PST
- 3 September 7, 2010 at 10:28pm PST
- 4 September 8, 2010 at 7:23pm PST
- 5 September 9, 2010 at 3:30pm PST
- 6 September 15, 2010 at 11:29am PST
- 7 September 16, 2010 at 3:04pm PST
- 8 September 22, 2010 at 2:45pm PST
- 9 September 25, 2010 at 7:14pm PST
- 10 October 1, 2010 at 6:09pm PST
- 11 October 9, 2010 at 11:23am PST
- 12 October 10, 2010 at 6:23pm PST
- 13 October 13, 2010 at 4:19pm PST
- 14 October 16, 2010 at 7:23pm PST
- 15 October 21, 2010 at 10:32pm PST
- 16 October 23, 2010 at 4:25pm PST
- 17 October 27, 2010 at 9:58am PST
- 18 October 24, 2010 at 12:16pm PST
- 19 October 29, 2010 at 12:58am PST
- 20 October 31, 2010 at 6:50pm PST
- 21 November 2, 2010 at 9:00pm PST
- 22 November 3, 2010 at 5:39pm PST
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.
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.
Roman is really excited about the rebuild!
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:
- Pro Taper or Renthal CR-Hi bars
- Moving from stock 13/47(3.61:1) to 13/50(3.84:1) ratio using Pro Taper or Renthal sprockets
- Sanaprene bar cones
- V-Force3 Reed Valve System
- Renthal or similar, possibly o-ring (a friend told me his horror story about o-ring chains and sand...)
- MX style front and rear fenders
- Guts Seat Cover this one or this one
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.
Ready to be blasted and coated tomorrow
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.
Got it out. I'll need to push the stem out of the clamp later.
Races are still in there. Not too sure how I'm going to get them out.
Finally! The frame is ready to be dropped off for blasting and powder coating.
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!
Old 2000 KDX200 forks next to my 'new' 2001 KX500 forks.
September 16, 2010 at 3:04pm PST
Just picked up the frame, swingarm and kickstand
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.
.33 inch depth
.33 in depth close-up (bearing depth for front swingarm bearings)
Front bearings done
Rear shock bearing--what a pain!
.19 inch depth
.19 inch depth close-up (bearing depth for lower swingarm bearings)
All bearings without seals installed
All bearings and seals installed (another shot)
All bearings and seals installed (before packing)
All bearings and seals installed (after packing)
Old stem race, major PITA, took about an hour to bang out.
New stem races installed.
Old stem bearing
New stem bearing on 2001 KX 500 stem
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.
Every single thread has been helicolied! On-top of that, done incorrectly. WTF happened to my cylinder!
I paid for a polish and port job. It looks like he didn't touch it.
Wrong size washers...
Stripped and destroyed plugs.
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.
Parts laid out.
Roman checking tire size.
October 10, 2010 at 6:23pm PST
2001 KX500 fork clamps and tubes installed.
Fork tube depth.
Front wheel mounted.
Engine cleaning, before
Engine cleaning, after.
New front sprocket. (Renthal 520 13-tooth steel)
Rear wheel mounted.
Rear aluminium sprocket. (Renthal 520 50-tooth aluminium)
New, clean chain guide and guards.
New Pro Taper EVO Carmichael bars.
Bars and new clamps mounted.
Done for today.
October 13, 2010 at 4:19pm PST
I decided to paint the top-end.
A good tape job
Hanging in the backyard, first coast of paint
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.
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.
The crank is still pristine, which means the seal should be good. The water must have gotten in from the cover side.
Installed new fork seal saver skins
Scotts sanoprene KX500 bar cones.
Acerbis front black fender.
Roman working on the clutch while I insert the main swingarm bolt.
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.
Destroyed stator bolts
All cleaned up and ready for paint
A little heat
Installed, torqued and loctite
Cleaned covers installed
Old 200cc piston next to new 225cc piston
Ring gap check .010
Cylinder bolted on
New head studs installed
Motor ready for installation in chassis
October 27, 2010 at 9:58am PST
I wanted wider footpegs. I picked up a pair of these.
D2Moto Footpegs $9.99
October 24, 2010 at 12:16pm PST
Exhaust cleaning begins
First time cleaning the expansion chamber
As good as we can do with a cheap polisher attatchment for my drill
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.
Airbox/boot and reeds
October 31, 2010 at 6:50pm PST
I was able to finish the controls, exhaust and carburator (35 pilot 150 main).
Packed the silencer and installed the exhaust system
Almost finished!--another shot
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.
It runs! First start, finally!
November 3, 2010 at 5:39pm PST
Extra long front fender bolts through lower clamps for number plate
Inside shot of long bolts with number plate on
Under front fender showing new long bolts
Notched number plate for brake line guide
Number plate installed
New grips with a touch of green
I'm planning on replacing the green shrouds with black in the very near future. Time to ride this Friday!
Completely assembled--another shot
Completely assembled--another shot