1991 KDX 200 Rebuild
- TheGriz
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1991 KDX 200 Rebuild
I haven't posted on here in a while, after selling my 2003 220. Well, today, I brought home a hot mess of a KDX. I like the "Liberty Dairybar" lettering on the side panels, perhaps it could help in finding an old owner or perhaps a back story. I'll be documenting the rebuild here...
Cracked cylinder, right above the intake manifold:
I wonder how accurate this is:
A good deal of rust:
Cracked cylinder, right above the intake manifold:
I wonder how accurate this is:
A good deal of rust:
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
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Re: 1991 KDX 200 Rebuild
MAN.
GOOD LUCK!!
GOOD LUCK!!
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
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- TheGriz
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Re: 1991 KDX 200 Rebuild
I will be needing a new intake manifold. I see a number of them on EBay but they appear to be for the H-series. Does anyone know if they cross over? They look similar...
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
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1991 KDX 200 Rebuild
I located a cylinder and piston. I think I'll send them to millennium for some love and TLC.
This was all that came out of the radiators: I guess that crack is in a cylinder water jacket...
This was all that came out of the radiators: I guess that crack is in a cylinder water jacket...
Last edited by TheGriz on 07:11 pm Sep 05 2016, edited 1 time in total.
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
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- Posts: 148
- Joined: 08:07 pm Nov 14 2014
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1991 KDX 200 Rebuild
This might get boring for some people, but I'm going to document the disassembly and reassembly. It helps me remember what went where... I haven't pulled the Kawasaki type power valves apart before. KIPS seems interesting, but not nearly as simple as a modern system.
Oops, something is missing!
I removed the cylinder head:
I need to do a little research. The power valve shaft is broken, right below the upper bushing. Maybe I can find a set of steel powervalves!
I'm trying to be careful with the rubber parts. I don't want to break things until I learn what I can source new.
I tried to remove the nut that secures the lever arm and it snapped the shaft at the threads:
Removed the center cover:
Removed the C-Clip
And rubber gasket:
Oops, something is missing!
I removed the cylinder head:
I need to do a little research. The power valve shaft is broken, right below the upper bushing. Maybe I can find a set of steel powervalves!
I'm trying to be careful with the rubber parts. I don't want to break things until I learn what I can source new.
I tried to remove the nut that secures the lever arm and it snapped the shaft at the threads:
Removed the center cover:
Removed the C-Clip
And rubber gasket:
Last edited by TheGriz on 07:10 pm Sep 05 2016, edited 1 time in total.
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
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- Joined: 08:07 pm Nov 14 2014
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1991 KDX 200 Rebuild
Removed the e-clips and the groove that the lever arm rides in:
Removed the T-Stat housing and behold, I broke another bolt. Time for me to slow down and start to soak everything in penetrating oil:
Removed the T-Stat housing and behold, I broke another bolt. Time for me to slow down and start to soak everything in penetrating oil:
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
- Supporting Member
- Posts: 148
- Joined: 08:07 pm Nov 14 2014
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1991 KDX 200 Rebuild
So I can remember what plug was last run in the bike:
Bleh!!
The head and squish band look pretty good:
Everything is going to soak in penetrating oil tonight:
The most used tools in my shop right now, are the parts washer and blast cabinet:
Bleh!!
The head and squish band look pretty good:
Everything is going to soak in penetrating oil tonight:
The most used tools in my shop right now, are the parts washer and blast cabinet:
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
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- Location: Eastern Tennessee
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1991 KDX 200 Rebuild
It won't be boring to me at all,my friend,I've always had a hankering to do what you're doing with this one but have yet to give it a try (not the most mechanically inclined person here,but my best friend and riding buddy is the head mechanic at my preferred local shop,so I'm learning here and there ),PLUS the KDX I recently picked up in trade (from the same friend) is a 1991 white one,so doubly interested in this thread. Subscribed. Have fun with it,can't wait to see more
1991 Kawasaki KDX200
2001 Kawasaki KL250 Super Sherpa
2003 Honda Shadow ACE 750
2008 Honda CRF250X
2001 Kawasaki KL250 Super Sherpa
2003 Honda Shadow ACE 750
2008 Honda CRF250X
- TheGriz
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- Posts: 148
- Joined: 08:07 pm Nov 14 2014
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1991 KDX 200 Rebuild
Good to hear. I did a similar step-by-step engine rebuild on a gasgas earlier this year and enjoyed documenting it. It really helped me reassemble as well.
I found new steel power valves here and just placed an order:
http://bdkraceeng.co.uk/tc/products.php?253
I found new steel power valves here and just placed an order:
http://bdkraceeng.co.uk/tc/products.php?253
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
- Supporting Member
- Posts: 148
- Joined: 08:07 pm Nov 14 2014
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1991 KDX 200 Rebuild
If anyone has an old governor shaft laying around (part number 49114-1067) I'd be interested in talking.
I suppose i could weld it up and chuck it in a lathe and re-thread it, but that sounds like a ton of work.
Edit - Just talked to a machinist buddy. He seems to think that making a new shaft will be easier and better than cobbling up the old one... more on that coming soon. Got to love a machinist!
I suppose i could weld it up and chuck it in a lathe and re-thread it, but that sounds like a ton of work.
Edit - Just talked to a machinist buddy. He seems to think that making a new shaft will be easier and better than cobbling up the old one... more on that coming soon. Got to love a machinist!
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
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Re: 1991 KDX 200 Rebuild
Great job on the pictures and info. It is quite interesting to me.
I was going to suggest BDK, but you already found them.
Correct plug is going to be an 8 heat range, unless you are riding in the desert or at high RPM often. For woods, an 8 is the ticket. B8ES for the cheapest, BR8EIX for the best.
I was going to suggest BDK, but you already found them.
Correct plug is going to be an 8 heat range, unless you are riding in the desert or at high RPM often. For woods, an 8 is the ticket. B8ES for the cheapest, BR8EIX for the best.
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
- TheGriz
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- Posts: 148
- Joined: 08:07 pm Nov 14 2014
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Re: 1991 KDX 200 Rebuild
Thanks. That should make it easier for me. I have plenty of plugs in the 8 range.
Question: Is the Governor shaft reverse threaded? That could have been my problem. I found this thread that says a 1995 shaft is left hand threaded, but my lever arm looks nothing like that.
http://www.kdxrider.net/forums/viewtopi ... rnor+shaft
Question: Is the Governor shaft reverse threaded? That could have been my problem. I found this thread that says a 1995 shaft is left hand threaded, but my lever arm looks nothing like that.
http://www.kdxrider.net/forums/viewtopi ... rnor+shaft
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
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1991 KDX 200 Rebuild
I know 1995 and newer are. I can not remember if it is for 1989 - 1994.
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Re: 1991 KDX 200 Rebuild
Yes, they are.TheGriz wrote: Is the Governor shaft reverse threaded? That could have been my problem.
'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
'90 KDX 200
'07 Vulcan 2000 Classic LT (totaled 4/25/15)
'82 Honda GL500 (sold)
'96 ZXi 1100 JetSki
'98 STX 1100 JetSki
- TheGriz
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Re: 1991 KDX 200 Rebuild
Thanks - I should have picked up a manual.
There was a gasket in the exhaust port:
Removed the water pump cover:
More nasty stuff:
Removing the kick starter:
There was a gasket in the exhaust port:
Removed the water pump cover:
More nasty stuff:
Removing the kick starter:
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
- Supporting Member
- Posts: 148
- Joined: 08:07 pm Nov 14 2014
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1991 KDX 200 Rebuild
So that I don't have to store nasty dirty parts and then spend an entire day of cleaning parts, I am trying to get them cleaned up as I go:
Back to the power valve:
It took some heat cycles to loosen this retaining bolt:
Removed the right side guide:
Removed the center valve bushing:
Removed the governor rod:
Removed the left side exhaust valves:
Teeth are in pretty bad shape:
Removed the center exhaust valve:
Removed the right side exhaust valve:
Back to the power valve:
It took some heat cycles to loosen this retaining bolt:
Removed the right side guide:
Removed the center valve bushing:
Removed the governor rod:
Removed the left side exhaust valves:
Teeth are in pretty bad shape:
Removed the center exhaust valve:
Removed the right side exhaust valve:
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
- Supporting Member
- Posts: 148
- Joined: 08:07 pm Nov 14 2014
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Re: 1991 KDX 200 Rebuild
I had forgotten that the KDX clutch is so unique...
Removed the cover:
Clutch Nut (22mm)
Noting the orientation of the spacer ring:
Removed the basket along with the steels and fibers:
Removed the cover:
Clutch Nut (22mm)
Noting the orientation of the spacer ring:
Removed the basket along with the steels and fibers:
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
- Supporting Member
- Posts: 148
- Joined: 08:07 pm Nov 14 2014
- Country:
Re: 1991 KDX 200 Rebuild
Last edited by TheGriz on 06:44 pm Sep 06 2016, edited 1 time in total.
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
- Supporting Member
- Posts: 148
- Joined: 08:07 pm Nov 14 2014
- Country:
1991 KDX 200 Rebuild
Clutch bushing:
Spacer/washer:
I removed the bolts that hold the right side crankcase cover on...
I found the pin from the governor shaft behind the clutch basket:
Removed the set screw that holds the governor shaft in place and removed the shaft:
Here is the broken pin. This pin rides in the centrifugal assembly (governor)"
Spacer/washer:
I removed the bolts that hold the right side crankcase cover on...
I found the pin from the governor shaft behind the clutch basket:
Removed the set screw that holds the governor shaft in place and removed the shaft:
Here is the broken pin. This pin rides in the centrifugal assembly (governor)"
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
- TheGriz
- Supporting Member
- Posts: 148
- Joined: 08:07 pm Nov 14 2014
- Country:
1991 KDX 200 Rebuild
I found these on my towel:
EDIT - Looks like the wave washer goes in the KIPS center valve. Still looking for a home for the flat washer.
EDIT - Looks like the wave washer goes in the KIPS center valve. Still looking for a home for the flat washer.
Last edited by TheGriz on 02:12 pm Sep 19 2016, edited 1 time in total.
1987 KDX 80
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300
1991 KDX 200
2005 GasGas EC250
2011 GasGas EC300
2008 KTM 300