1991 KDX 200 basket case.

eprovenzano · Post by **eprovenzano** » 12:20 pm Apr 01 2016

Thank you Friedom... That answers that question...

In keeping with the blue frame and white plastic, I was looking for some graphics for the tank shrouds. On Ebay, factoryefxshop had what I wanted, but it was on a green background... It would be perfect if my plastic was green... I took a chance and asked if they could produce the same graphic on a white background... I received an answer a few days later... yes we can, and here is the link to the listing on ebay... so yes I ordered a set... I just wanted to pass along their ebay store incase anyone needed something for their steeds... http://www.ebay.com/usr/factoryefxshop? ... 7675.l2559.

Just and FYI here is the KDX graphic in white... http://www.ebay.com/itm/KDX-200-Radiato ... A1&vxp=mtr

eprovenzano · Post by **eprovenzano** » 02:58 pm Apr 02 2016

That's to everyone here I've relocated the CDI to its proper location.

I've started "fixing" the plastic as you can see one of the shrouds was broke. I've been able to weld the broken price bank together on... Next is to patch the hole. I've also welded a large crack and filled in s missing chunk on the headlight mask. Due to the horrible condition of the plastic I've made the decision to paint (plastic primer, plastic paint and plastic clear coat) the plastic. Since I have to paint the plastics, I'm grafting a black KTM rear fender, it too needs to be white.

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eprovenzano · Post by **eprovenzano** » 12:08 pm Apr 05 2016

Getting ready to finally fire her up... Just need to tighten up several loose ends.. I was wrenching on my KTM changing out the tranny oils getting ready for a weekend ride and decided I may as well fill the tranny on the KDX too... As I'm wrenching I look back at the KDX and see oil pouring out of the clutch cover. DAMN IT... I didn't remove the cover so I ASSumed it was good... I ASSumed incorrectly... I'll pull it tonight and will use high temp silicone to fix the leak, meanwhile I wasted a quart of oil... I know better than to not check everything, especially
something as simple as the clutch cover gasket ... Lesson learned... again

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Friedom · Post by **Friedom** » 09:22 pm Apr 05 2016

I've got a set of white shrouds in pretty decent condition looking for a good home. Got them from SS109, but didn't look good with my green tank. LMK if you're interested.

Fun Wheel Drive

eprovenzano · Post by **eprovenzano** » 05:42 am Apr 06 2016

Friedom wrote:I've got a set of white shrouds in pretty decent condition looking for a good home. Got them from SS109, but didn't look good with my green tank. LMK if you're interested.

Fun Wheel Drive

PM sent

eprovenzano · Post by **eprovenzano** » 05:48 am Apr 06 2016

I went over the bike tightening the bolts I knew I put in finger tight. I also pulled the clutch cover. The gasket was stretched and was laying below the cover, hence the leak. I cleaned it up, applied some HI-Temp RTV silicone to hold the gasket in place and reinstalled. I'm letting it dry overnight but we should be good to go.

I went through the last of the boxes of parts... The parts left to install is getting smaller. 1st attempt to start the bike planned for Thursday

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eprovenzano · Post by **eprovenzano** » 12:05 pm Apr 09 2016

Pulled the triple clamps. Steering stem bearings was a little dry and quite rusty. I wondered why there was play in the front end...

After a little sweat equity out with the old and in with the new... Now the front end is nice and tight. To remove the lower bearing, cut the cage removing all the bearings. There there will be a lip to which you can get a good punch or chisel onto... Turn the clamp upside down, in your bench vise, and begin working what's left of the bearing off the shaft. The lower triple of the KDX does not give much room to work both sides of the bearing. I used a little heat from a propane torch, and was able to get the old bearing off... To install the new one, turn the old on upside down, and use it to drive the new one into place... (after thoroughly greasing the new bearing)

Chain lubed and installed. Shifter installed. Found a broken bolt on rear master cylinder. Pulled out my left handed drill bits. The broken bolt backed out without a problem. Installed now bolt and adjusted the rear brake. Working on getting the KTM fender to mount up. Then the sanding party can begin.

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eprovenzano · Post by **eprovenzano** » 08:26 am Apr 12 2016

I fully undersand the issues associated with painting bike plastics... usually they look like

Well the plastic I started with was so bad, I have no choice... I've stripped off all the black paint to expose the original beaten white plastic. I've sanded with 180 grit revealing some decent parts and others not so decent... somewhere in it's lifetime, it went down hard on the left side... the headlight bezel was badly damaged, and cracked. One of the tabs on the left shroud was broken, and a piece of the shroud was missing... I tried to plastic weld them together using a soldering iron... yes it worked, yes it doesn't look the best...

but it's what I have to work with

Here is the shroud with the broken tab welded and the hole patched I've yet to sand it so yes it will look much better before any primer will be sprayed

Again I had a sanding party with the plastic. My approach is to use Krylon paint for plastic. I've started with their white primer. Here is after one coat. Next will be to lightly sand, and them a 2nd coat of primer. I'll then hit it with steel wool, followed by two coats of white plastic paint, and then finally 2 coats of clear.

No I'm not looking for a "restored" bike... this is a buddy bike which will be dropped from time to time. If the plastics get scratched... so what... at least any scratches will still be white... Although it would be nice if it turned out close to this..

eprovenzano · Post by **eprovenzano** » 09:00 am Apr 20 2016

I took some time off for a mini vacation with the wife, but now I'm back on the KDX project. Previously I fitted an old KTM rear fender onto the KDX thanks to my heat gun... It was an old scratched black fender that I kept wanting to throw away, but for some strange reason never did... All the plastic has been cleaned, sanded, prepped and primed with two coats of white plastic primer. Once dry, they were rubbed down with steel wool and then shot with two coats of white paint plastic They will be rubbed down with steel wool again then then one to two additional coats of paint and then the clear will be applied. The new KDX shroud graphics will be installed and then it's time to finish reassembly and fire up the ol girl...

We're getting close. I don't want to rush the paint, as it takes a full week to completely cure.

eprovenzano · Post by **eprovenzano** » 09:10 am Apr 20 2016

eprovenzano wrote:
Friedom wrote:I've got a set of white shrouds in pretty decent condition looking for a good home. Got them from SS109, but didn't look good with my green tank. LMK if you're interested.

Fun Wheel Drive
PM sent

For some reason I cannot respond to the PM you sent...

I appreciate the offer, but I decided to continue to repair this bike as cheaply as I can... I've used a soldering iron to weld a few patches on the shrouds and headlight bezel. With me using a black fender from a KTM, plus the horrible shape of the plastic, I have no choice but to paint everything. So with that in mind, I'm just going to use the beat up / broken, redneck repaired shrouds that I have...

Again, I appreciate the offer, and who knows may take you up on the offer in the future.

eprovenzano · Post by **eprovenzano** » 10:02 am Apr 21 2016

We're coming down the home stretch.. I sprayed a 3rd coat of paint, and 2 coats of clear last night. Notice the rear fender is an old black KTM rear fender I repurposed... I ride orange, so at least the KDX has some KTM parts too....

I also fixed the worn choke. It is after all 25 years old... I did some research and found if you tied a wire around the base of the choke, it helps for the chock to engage like it did when it was newer.. so here is my repair / mod. I used a piece of stainless steel wire around the base fo the choke. Previously when you pulled up on the choke, it would not click into place and stay on... After the repair / mod, when you pull the choke up, it clicks into place and stays up as it's supposed to... cheap simple fix... Just how I like em...

eprovenzano · Post by **eprovenzano** » 08:04 pm Apr 21 2016

Decided to put the plastic back into the bike so it looks like a bike again...

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eprovenzano · Post by **eprovenzano** » 08:06 pm Apr 21 2016

Friedom for some reason I cannot send a PM. Yes I'll take the shrouds please send me an email. eprovenzano@yahoo.com.

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eprovenzano · Post by **eprovenzano** » 09:06 am Apr 24 2016

I finally had a chance to put fuel in the tank and fire her up. I put in 1/2 a gallon of fresh premix, flipped her onto reserve pulled up on the choke, and gave her a few strong kicks. She came to life for a seconds when I notice fuel pouting out of the carb. The gasket on the float bowl is not sealing.... Plus the petcock is leaking ... I had to quickly drain the tank as fuel was going everywhere...

Damn so close, yet so far. Oh well I have a little more fiddling to do....

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Friedom · Post by **Friedom** » 09:24 pm Apr 24 2016

Hehe. Went out for a ride yesterday. We started with filling up the tank for a nice long ride, then noticed it was dripping.
A lot.
From the right side of the tank.
Stress Crack about 6" long under the shroud.
So we went home, pulled out the spare white tank that I got from SS109 (thanks man!), swapped fuel and petcocks, got it all mounted up and rode off into the sunset.
Soooooooooo glad that didn't happen on the trail.

But this is about you. You're almost there :)

Fun Wheel Drive

eprovenzano · Post by **eprovenzano** » 05:54 am Apr 25 2016

Friedom I love your comments and especially that you're getting more comfortable with the 2 honey... Looking forward to hearing you dominating the off road world... Lol

I'm off on a business trip to Denver this week, so she'll have to wait until I get back...

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Friedom · Post by **Friedom** » 05:58 pm Apr 27 2016

Oh you'll hear me alright. It's so stinkin loud! I'm trying to find a better silencer than this weird cobra thing that I have. Looking at a CL ad for an H model FMF pc2 for sale local. Wonder if it's different than the e series.

Fun Wheel Drive

david · Post by **david** » 09:20 am Apr 29 2016

Totally different.

Friedom · Post by **Friedom** » 10:53 am Apr 29 2016

Thanks.

Fun Wheel Drive

eprovenzano · Post by **eprovenzano** » 01:16 pm May 01 2016

I spent some quality time with the KDX... Previously the petcock was leaking and the carb was leaking. The carb was leaking either out of the drain bolt or the seal of the float bowl. I pulled em apart cleaned em and added a little RTV silicone to promote a good seal. I took the petcock apart, cleaned it and again added a tab of RTV.

I put the carb on and the tank, added a little premix and had no leaks. I flipped on the choke and she came to life within 3 kicks...

SHES ALIVE!!!!!

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