1991 KDX 200 basket case.

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
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eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

I need to go over every nut and bolt before I'll let anyone ride it. When you start with just a frame, it's probably a good idea to recheck your work. It's easy to just hand tighten something thinking I'll get they later and forgetting about it. I need to mount my repurposed KTM front fender, replace a few mix matched bolts ( that drives me crazy) then I'll take it around the block for it maiden voyage


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

Here's a pic with the KTM front fender.

Image

I like the look, and so far with the fuel left on, no leaks. Just a few more small bits to do, then finish breaking in the top end and then it be time to get her dirty.




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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

I finished the bike Sunday afternoon and ran it through its 1st heat cycle. When I came home from work Monday just for giggles I tried to start the Ol 2 honey. It started on the 1st kick

Here's a quick video of her running...
http://vid18.photobucket.com/albums/b12 ... G_1204.mp4

Looks like I need to reseal the exhaust at the cylinder base... :lol:

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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
Friedom
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Re: 1991 KDX 200 basket case.

Post by Friedom »

It's incredible how easy these bikes start one everything is in order, huh!?

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eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

That's because we are master garage mechanical hacks. Or simply stated its amazing they actually start and run in spite of our mechanical prowess :shock:


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
david
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Re: 1991 KDX 200 basket case.

Post by david »

How's this for easy to start. Sat for 2 years in the shed in the back yard. Put gas in it, choke, kick, vrooom.
https://vimeo.com/165197242


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'81 KDX 175
'90 KDX 200
'07 Vulcan 2000 Classic LT (totaled 4/25/15)
'82 Honda GL500 (sold)
'96 ZXi 1100 JetSki
'98 STX 1100 JetSki
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

That's too funny!!!! :supz: :lol:
1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
eprovenzano
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1991 KDX 200 basket case.

Post by eprovenzano »

I'm almost there... I ran it through another heat cycle. (Started on the 1st kick) Also ran it through all the gears. I would have gone for a spin around the block but it was pouring down rain...

One of the last things to do is fabricate a mud flap. Yes I'm too cheap to buy one... I'll fab one... I just need to find a suitable piece of rubber. I also need to get a headlight bulb. I have the thread on bulb replacements saved. For a buddy bike I prefer to have the light on. I've found It's easier for me to see the bike behind me if the light is on.


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
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Julien D
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Re: 1991 KDX 200 basket case.

Post by Julien D »

I do one heat cycle just to check for leaks, and then ride. All I do is try to avoid steady rpms for the first hour or so.

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Friedom
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Re: 1991 KDX 200 basket case.

Post by Friedom »

Yeah the heat cycle thing has kind of been debunked a little. One the rings seat, just make sure the bolts are still tight and do a few short oil changes. Though the tranny oil isn't involved in the top end, so I'm not sure how that factors in either.

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Sullyfam
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Re: 1991 KDX 200 basket case.

Post by Sullyfam »

Agreed. Heat cycle/breaking in a new piston is almost as polarizing of a topic as best premix.


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eprovenzano
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1991 KDX 200 basket case.

Post by eprovenzano »

I agree but staring with an engine in pieces, an empty frame and several boxes of parts... I'm just tickled that it runs as well as it does. [emoji41]


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
eprovenzano
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1991 KDX 200 basket case.

Post by eprovenzano »

I finally took the 2 honey for a ride around the block... Let's get something straight 1st... I've been riding big bore smokers for most of my adult life... This ain't like my KTM 380... But it's not supposed to be either. [emoji4]. This is the perfect buddy bike. Just enough power to get you there, not too much to over power you, and more than enough to put a smile on your face while you enjoy the ride. Starts 1st kick, idles well and it just a fun little bike

The wife was admiring my work, and said Hey cheap ass, couldn't you at least get a new shroud instead of fixing this one... Any other time she's complaining I spend too much on bike parts.... I cant win.... [emoji855]


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

This bike has now the been renamed "The one kick wonder"... Flip on chock and give her a kick... Bam. She just sits there and purrs. With the stock exhaust and silencer, it's so quiet...

My son took it for a spin (He rides a KTM 300) and came back laughing. "It's a toy... but I love it". Just enough power to keep a novice from doing too much.

My wife has asked if I thought she could ride it I'll have find and open field and turn her loose... hmmm or maybe a root infested rock garden :lol:

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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
MotoArts
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1991 KDX 200 basket case.

Post by MotoArts »

A little personal opinion on using RTV around gasoline... DON'T!

From experience, and, well, maybe more than once before I learned my lesson...
RTV will turn to snot when used for gasoline sealant. It will find its way into the damnedest of places (ie. pilot jets, Holley 4V metering blocks on vintage automobile carburetors) and make you say words that you didn't know you knew.

Please do yourself the favor and reseal those leaks correctly. It will bite you in the buttocks at the worst time. Maybe not today, or tomorrow, but... :twisted:

I think the bike came out killer! My son and I have been following the build since its previous home was familiar.
Congrats!
'97 KDX220, '84 YZ125, '81 YZ250, '78 RM250C2, '80 RM100T, '04 KTM 250SX,
'82 Yamaha Seca 650 Turbo, survivor
eprovenzano
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1991 KDX 200 basket case.

Post by eprovenzano »

Thanks for the kind words MotoArts.

I agree RTV wouldn't have been my 1st choice... I did clean everything really well and added the RTV more or less to keep the gaskets in place when I reassembled the carb and petcock. Since applying the RTV I've ran the bike multiple times and so far so good. If all goes as planned it will be getting dirty this weekend.


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
Friedom
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Re: 1991 KDX 200 basket case.

Post by Friedom »

So I've got those shrouds ready to ship... hehe

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eprovenzano
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1991 KDX 200 basket case.

Post by eprovenzano »

Friedom please send me an email. Eprovenzano@yahoo.com so I can send you some $$$ and an address.


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
eprovenzano
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Posts: 200
Joined: 12:00 pm Nov 21 2013
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Location: Wellsburg, WV

Re: 1991 KDX 200 basket case.

Post by eprovenzano »

Thankd Friedom the shrouds have arrived... There's nothing like putting on new parts.


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1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
eprovenzano
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Posts: 200
Joined: 12:00 pm Nov 21 2013
Country:
Location: Wellsburg, WV

1991 KDX 200 basket case.

Post by eprovenzano »

The weekend ride was postponed a week due to 3+ inches of rain. Our normal riding area would be a swamp So my son has the KDX in some trails behind the house. Let's see how she holds up


Sent from my iPhone using Tapatalk
1991 KDX basket case... being rebuilt
2001 KTM EXC 380... two stroke heaven
2000 KTM EXC 300, son's
1993 Kawaski Bayou 400 4x4
2008 Yamaha Vstar 1100 Silverado
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