1991 KDX 200 basket case.

eprovenzano · Post by **eprovenzano** » 03:55 pm Jan 16 2016

I picked up a 91 KDX 200E basket case for a whopping sum of $150.

As you can see it was completely dissembled when I picked it up. I did a quick inventory to see what was missing. Other than the exhaust (which I new about) it's missing an air filter.

I wanted to get it back into s rolling chassis.

And then dug into the top end. I knew the left exhaust valve was broken. It'd just sad to see them all laid out...

The valves will be replaced with a new steel set. The piston has a slight crack so it too will be replaced. All other parts were thankfully meticulously bagged and tagged...

The plastics will need a lot of elbow grease to save them. But after a lot of sanding and painting we will see...

I'll keep postings updates as I bring her back from the dead

Sent from my iPhone using Tapatalk

eprovenzano · Post by **eprovenzano** » 10:38 am Jan 17 2016

Just a few other details about the "basket case" The tires are 90%, the chain and sprockets are new, brake pads are 80%. New clutch basket plates and springs... The electronics all look good, no evidence of broken wires Thanks goodness the PO tore it down when he did... I found a crack in the piston skirt and evidence of a seizure

. I did a quick cleaning of the cylinder with a green scotchbrite pad. No the cylinder isn't perfect, and if this were to be my main ride I'd have the cylinder redone, but since this will be a buddy bike, I'll clean up the cylinder and put in a new piston, rings, and needle bearing.

With the top end off the bike I have the opportunity to access the bottom end. There is zero up and down play in the connecting rod, no play in the crank end bearings, plus the bike shifts perfectly... To say the bottom end is tight is an understatement...

Mechanically I'm sure I can bring the Ol girl back and make her a reliable bike. Cosmetic's are a different story... To say the plastics are rough is really being kind. New plastics are not in the budget... I'll be using a rattle can to repaint everything. I'd thinking about repainting the frame in the OEM blue color. Now for the plastics, they've been painted (several times) and look ragged... I will sand, prime, sand, prime, paint and spray a clear coat. My question, what type of paint should I use (I'm leaning towards Krylon Fusion) , but I'm open to suggestions...

My plans are for this bike to be a buddy bike... My son-in-law will be the main rider... but it will be nice to have a spare buddy bike in the stable.

eprovenzano · Post by **eprovenzano** » 03:44 pm Jan 17 2016

Got some time to spend looking at the KDX. Since I'm not the one who dismantled the bike. I wanted to take a little more time to do a parts inventory, and to reconstruct the bike in my mind to ensure I have everything I need. I may need to replace the steering bearings. The PO had the bike disassembled to paint the frame, so I'm not sure if the triples are tight or just quickly reinstalled... Also the swing arm bearings are non existent... Again it just may be a quick reinstall not sure...

Looking at the badly beaten plastics I'm sure I'll be standing layers of paint off. I tried to scrap it back to find the original color... Nope too many coats. The rear fender is steel off of God knows what... It's serviceable but... I may look at my hoard of KTM plastic and see if I can utilize some black plastic I have lying around.

Sent from my iPhone using Tapatalk

eprovenzano · Post by **eprovenzano** » 08:20 am Jan 19 2016

Well let the spending $$$ begin.... I just ordered a set of steel KIPS valves from BDK Racing http://bdkraceeng.co.uk/tc/products.php ... 12c8e6ea4b... I'm looking forward to the replacements... I'll begin the cleanup of the rod, and front valve. I'll wait until I get the new KIPS valves before ordering the rest of the parts needed to bring the Ol girl back to life.

sarrant · Post by **sarrant** » 01:23 pm Jan 19 2016

Looking at the badly beaten plastics I'm sure I'll be standing layers of paint off. I tried to scrap it back to find the original color

Definitely is the rare white KDX under there, though

eprovenzano · Post by **eprovenzano** » 01:51 pm Jan 19 2016

sarrant wrote:
Looking at the badly beaten plastics I'm sure I'll be standing layers of paint off. I tried to scrap it back to find the original color
Definitely is the rare white KDX under there, though

No I think under the black is a coat of primer... I'll know more this weekend when the sanding party begins...

sarrant · Post by **sarrant** » 02:00 pm Jan 19 2016

Blue frame = White KDX.

eprovenzano · Post by **eprovenzano** » 02:17 pm Jan 19 2016

sarrant wrote:Blue frame = White KDX.

Hmmm I may need to dig a little deeper into the plastics to see is they are indeed white under all the crappy black paint...

david · Post by **david** » 02:33 pm Jan 19 2016

Yep, you have a White KDX. It's a lot harder to find all the plastic for those, but it's been done in the last few years by one of our members.

You got your money's worth in just the tires. I say you're ahead already and if you can keep your expenses under $700-800, you will come out even.

eprovenzano · Post by **eprovenzano** » 02:40 pm Jan 19 2016

Well after doing a quick google of 1991 White KDX's I can begin to fully appreciate what I have.... Due to budget constraints new plastics are not in the budget, so I'll be using a rattle can on the plastics. Now i know the color of the plastics will be white. The sanding party starts this weekend...

Sent from my iPhone using Tapatalk

david · Post by **david** » 02:50 pm Jan 19 2016

You can also try to refurbish the plastic. Sand it down to white and then smooth with 1500-2000 grit. You can wave a propane torch over the surface and it will melt the fine scratches and bring back a semi gloss shine to it. Much more durable than paint.

eprovenzano · Post by **eprovenzano** » 02:59 pm Jan 19 2016

david wrote:Yep, you have a White KDX. It's a lot harder to find all the plastic for those, but it's been done in the last few years by one of our members.

You got your money's worth in just the tires. I say you're ahead already and if you can keep your expenses under $700-800, you will come out even.

I agree... The only real issue I can find is the broken KIPS valve. A new set has been ordered, next will be a complete Wiseco top kit, and paint... Again if this were my only ride, I'd have the cylinder redone... but its serviceable as it is. The only real expenses I have are the KIPS valves and the top end. I'm expecting an all in investment of around $550.

I did think about parting her out, but she's just in too good of a shape.

Sent from my iPhone using Tapatalk

eprovenzano · Post by **eprovenzano** » 03:01 pm Jan 19 2016

david wrote:You can also try to refurbish the plastic. Sand it down to white and then smooth with 1500-2000 grit. You can wave a propane torch over the surface and it will melt the fine scratches and bring back a semi gloss shine to it. Much more durable than paint.

Yea that will be the 1st attempt.. Painting will be the last resort. There's a lot of layers of black paint to remove. Lol

Sent from my iPhone using Tapatalk

david · Post by **david** » 03:07 pm Jan 19 2016

Bolt the plastics on (because it's hard to hold them) and take the bike to high pressure car wash and blast off the black. I did that with a friends XR250 that the previous owner painted black. I got it all off, plastics and frame, it cleaned up real nice.

eprovenzano · Post by **eprovenzano** » 03:15 pm Jan 19 2016

david wrote:Bolt the plastics on (because it's hard to hold them) and take the bike to high pressure car wash and blast off the black. I did that with a friends XR250 that the previous owner painted black. I got it all off, plastics and frame, it cleaned up real nice.

Not a bad idea... It surely can't hurt to try...

Thanks

sarrant · Post by **sarrant** » 04:26 pm Jan 19 2016

Brake fluid soak will also help break up the paint without damaging plastic.

eprovenzano · Post by **eprovenzano** » 01:16 pm Jan 20 2016

I just received an email from Brock of BDK Racing... My steel KIPS valves are on the way...

He recommended a deep and thorough cleaning of the location hole in the bottom of the valve cavity, as that's usually what causes the issues of the sticking valve. Since the weather is bitterly cold, I'll bring the cylinder into the house and give it a proper cleaning, including the piston bore. I still need to clean up the center valve and remove the the old base gasket from the cylinder. Once the valves arrive, I'll drop in the new valves, and we'll be one step closer to having a working motor again.

eprovenzano · Post by **eprovenzano** » 07:32 pm Jan 23 2016

While I wait for the KIPS valves to arrive, I pulled the old plastics into the house... The actual color under the nasty black paint is white... I'm going to try to remove the paint with Easy Off oven cleaner. I've read both good and bad reviews... I'll report my findings

Sent from my iPhone using Tapatalk

Friedom · Post by **Friedom** » 12:17 am Jan 24 2016

I don't recommend baking them..

Joy to the world!

eprovenzano · Post by **eprovenzano** » 10:01 am Jan 24 2016

Friedom wrote:I don't recommend baking them..

Joy to the world!

I'll keep that in mind...

As a test I sprayed the headlight number plate and the front fender... I let them sit overnight. When I looked at them this morning I wasn't impressed. It "looked" the same as it did after I sprayed them. I utilized a hose with hot water and the paint just pealed off, and the plastic has no damage. So I sprayed down the rest of the plastic and I'll let it sit for at least 12 hours before spraying them down

Sent from my iPhone using Tapatalk

KDXRIDER.NET

KDXRIDER.NET