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 »

He came back laughing and saying it's just too muddy, but the KDX performed as expected. Looking towards a full flogging next 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
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

Son keeps taking the KDX out behind the house in some of our trails.. Yesterday he came back and pointed to a leak near the left side KIPS cover. The engine has some fresh spooge on it... It will be a simple fix. This is why I have no issues with him riding it a bit... When we do go for a long ride, I want the bike to ne as mechanically correct as I can make it. I hate to fix something on the trail that I should have corrected before the ride. If you're invited to ride with me, please don't show up to the trailhead and start wrenching on your bike... I will conveniently forget to notify you of the next ride. I understand things break.. no issues, I'll do what ever I can to get you through the day... but if it's something that should have been corrected prior to the ride... :mad: My riding time is limited, so I want to ride, not fix bikes.

So far only a few minor glitches.. nothing a quick little maintenance can't handle.
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 »

Well today was the day... I'm on my KTM 380, my son on a KTM 300 and his buddy on the KDX. Part way through the day I get a rear flat. I head to the truck and tell my son and his buddy to continue to ride...
Our terrain is a lot is clay soil, with lots of rocks. We've had a lot of rain so the trails were swamped. The KDX has done everything we've asked it to do. My sons friend is a novice rider and is having the time of his life. My son is loving it that he gets to introduce his buddy to a sport he loves. The KDX has been flawless. He'd dropped it a few times (as expected) it just takes a liking and keeps on ticking.

Other than one small nut that came off of the exhaust, and the gas cap seal leaking it's been perfect. Great project with great results.

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And this is what happens when you get a flat tire. You take a selfie and load the bike into the trailer

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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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jaywylie
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Re: 1991 KDX 200 basket case.

Post by jaywylie »

Looks like a good time, even with a flat tire!
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

Just a little update... the KDX continues to hold up quite well.. Its been out multiple times with multiple riders and has not let us down. The only issue I've had is a leaking petcock (replacement ordered), and I've struggled to keep the chain in adjustment. I have to re-tighten before every ride. During the past ride, my son (on his KTM 300 and his buddy on the KDX) noticed something was wrong with the rear wheel... The found the rear sprocket was worn down to nubs... I think the loose chain has caused the rear sprockets to wear at an accelerated rate... Oh well I have a spare sprocket in the parts bin.... Being a part hoarder comes in handy from time to time... :lol: I'll replace the sprocket and look at the chain adjusters to see if I can determine why is getting loose. :grin:
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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Re: 1991 KDX 200 basket case.

Post by MotoArts »

Good to hear! Bike looks cool! How's the plastic holding up?

That chain... it's most likely toast by now.
Last year when my son had his DRZ125 Suzook (and it's eye watering 8hp output), we put a new Moose gold chain and steel JT sprockets on it. That chain literally required adjustment every ride. After, oh, I'll bet 8-10 rides, it was able to be pulled off of the rear sprocket.
Of the 40 or so bikes I've owned over the years, that was the worst POS chain I had ever seen.
:sad:

Yea, what the heck. Drape that chain over your used sprocket. Ya never know, it might be close (to fitting). Keep your eyes peeled for a new sprocket set. I scored an ebay rear NOS Kaw KDX steelie for 8 bucks... delivered...
'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 »

Yea I'll "baby" it through this season and replace both sprockets and chain this winter. The plastic is doing OK... It's not new looking anymore, but it's passable. (I'll repaint it again this winter just because I can... Lol )

The DRZ 125... Yep I picked up one that was cooked. The tires were bald from being ridden on the road so much. It had an FMF exhaust. Unfortunately they didn't adjust the jetting for the new pipe. (It was too lean) Add that to WFO and the piston melted, (there was a huge hole on the piston)... I rebuilt it and sold it to a guy looking to get his son his 1st bike... Yep they're slow under powered, brakes are sketchy, but perfect for 1st time riders.


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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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Re: 1991 KDX 200 basket case.

Post by MotoArts »

Not to hijack, but had to share my favorite pics of him on that little bike from that "one" good snow day we had last year. He outgrew it so darned fast or we'd probably still have it.
He owns the CR in my signature now, but prefers my 220 since it's much softer all around.

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'97 KDX220, '84 YZ125, '81 YZ250, '78 RM250C2, '80 RM100T, '04 KTM 250SX,
'82 Yamaha Seca 650 Turbo, survivor
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

I had the same issue... Son's 1st bike was a TTR 125. Six months after getting the bike he had a growth spurt and quickly outgrew the bike. He then moved onto a YZ 125.


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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 »

We had the KDX out over the weekend. Temps in the mid 90's with high humidity. The old girl never missed a beat. Even with the replacement of the rear sprocket (50 tooth to a 48) she never let us down. Other then a tip over which broke a brake lever, she's ready for more. A few guys had to inspect her as they had one back in the day. They even asked about the power valves... Yep they've been replaced. They loved the old girl as they had fond memories of their KDX's


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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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TheGriz
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1991 KDX 200 basket case.

Post by TheGriz »

I enjoyed reading your whole thread. I too started with a hot mess (though mostly put together). The biggest problem I've had is that once i restored a few parts, I couldn't just be satisfied with that, I've had to give the full treatment to all the parts.

Love the color scheme! Good work on getting her back together.
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

Thanks Griz... Restoring bikes can really be satisfying .


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Last edited by eprovenzano on 11:02 am Oct 17 2016, edited 1 time in total.
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 »

Just a long term update...

The KDX has been ridden by several of my son's friends. One in particular has ridden it quite a bit... in fact she's been ridden hard, and she never, never skipped a beat. The only issue I have is the fuel economy seems low, but it runs so well I'm not touching the jetting

My son's friends are now all hooked on bikes and have all purchased their own. So last weekend my son-in-law rode it. Again she performed as expected... conditions were great. We had a little rain a few days prior to the ride, but we had a dry sunny day, temps in the high 60's.

Of course everyone had to take the KDX for a spin... One rider a seasoned MX rider could be heard laughing the whole time while on the bike... he said it's a cruiser that just puts a stupid grin on your face... it's so much fun...

The rescued KDX has almost finished its first season as my buddy bike. The only issues have been replacement of a warn rear sprocket, replacement of a broken front brake lever, and replacement of a few bolts that vibrated loose.

The painted plastic has held up pretty well.. yes it dinged and scratched. The paint on the tank has bubbled and flaked off... big deal... I'll pull it apart this winter, repaint everything and will have her ready for another season...


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Last edited by eprovenzano on 11:04 am Oct 17 2016, edited 1 time in total.
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
javjacob
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1991 KDX 200 basket case.

Post by javjacob »

TheGriz wrote: The biggest problem I've had is that once i restored a few parts, I couldn't just be satisfied with that, I've had to give the full treatment to all the parts.
I am the same way, I don't know when to stop.
2000 Kawasaki KDX220R
1996 Kawasaki KDX200
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

Just thought I've give a long term update...

Of course she sat all winter... I was busy (lazy) and didn't touch her... Pulled her out of the shed, flipped on the choke and on the 3rd kick she came to life... The gas in her is old & stale, but still fires up life like she was only sitting for a few days. :supz:

As far as the painted plastic... the tank looks like a 14 year old with acne... Oh well, I'll run her as is, and will wait until the end of the season, and give the plastics a fresh coat of paint... I do need top fix an exhaust leak at the cylinder and header pipe connection. I'm sure the O rings are shot, and its missing the copper crush washer. I'll try a little high temp RTV... if that doesn't hold, I'll get some replacement O-Rings and a crush washer.

The ol girl is like an old Timex watch... "Takes a licking and keeps on ticking" :bravo:
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 »

Long term update... going into her 3rd season, she has done everything I could have asked for. She’s never let me down. Many riders have ridden her, and she put a smile on everyone’s face.

This winter the plastics have been repainted just to freshen it up, the issue with the chain coming loose has been corrected, the exhaust leak fixed as well as the gas cap seal replaced. Still starts cold by the 3rd kick. I m getting some fuel out of the overflow as the float is too high. Other than that she’s a joy to ride.


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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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Re: 1991 KDX 200 basket case.

Post by KDXGarage »

Heck yeah! I am glad to hear she is stlll going for you!
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
eprovenzano
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Re: 1991 KDX 200 basket case.

Post by eprovenzano »

Image

Image

All ready for another season


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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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Re: 1991 KDX 200 basket case.

Post by KDXGarage »

Looking good!

She is showing too much leg. Tell her to pull up her fork boots. :razz:
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
John_S
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Re: 1991 KDX 200 basket case.

Post by John_S »

I enjoyed reading the updates. Congratulations on the KDX!! You're making fans of the bike that might never have had a chance to ride one.
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