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.

Dirty


Clean


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

Before


Put it together

After


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

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!

Unwrapped


Another frame shot

Frame


Swingarm

Swingarm


Another swingarm shot

Swingarm


Kickstand

Kickstand


September 22, 2010 at 2:45pm PST

OEM parts arrived!

Packages


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

Parts


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

Front


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


Cleaned????

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.

Spread


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

Before


Engine cleaning, after.

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

Before paint


A good tape job

All taped up


Hanging in the backyard, first coast of paint

First coat


After paint, three coats

After


After paint, three coats

After


October 16, 2010 at 7:23pm PST

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


Before

Before paint


After

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.


Before

Before


After

After


Before

Before


After

After


October 23, 2010 at 4:25pm PST

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


Chemotherapy

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

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

Pistons


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!