It begins! '90 KDX200 rebuild

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SS109
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It begins! '90 KDX200 rebuild

Post by SS109 »

Well, the time has finally arrived! My KDX is getting the full rebuild treatment and I do mean FULL rebuild. Completely rebuilding the engine, suspension, plastics, and accessories.

My baby is currently minus forks and shock as they're out getting re-valved/rebuilt right now by Don at ZR1. I have parts on order and just waiting on everything to get here. I'll be posting up pics as I go and maybe ask for a little help or even some opinions on things.

Here is the starting point. Let the fun begin! :supz:

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Post by Mr. Wibbens »

Never seen one with the BMF chain guard still attached
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Post by SS109 »

Yeah, that is one of the things that will be saying bye-bye! :mrgreen: Oh, yeah, I do plan to try an update the styling a bit.
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Post by Julien D »

I kept the chain guard on mine. Figured it couldn't hurt tryin to get some longevity out of a cheap chain in the mud. Good luck with the rebuild :)
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Post by kdxquebec »

Yep. Lots of fun! Keep us updated.
'89 KDX 198cc '03 Gasgas Ec250 '13 Husaberg Te300
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Post by michael »

Just got through mine mid last year. Its quite apleasing feeling when its all done, roll her out the shed for a ride, And then ya hit a buried log, bend the bars scratch the new plastics....... I won't go on.
I'm glad i endured it.

All the best man, enjoy ;-)
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Post by kdxquebec »

The first cut is the deepest, baby I know :wah:
'89 KDX 198cc '03 Gasgas Ec250 '13 Husaberg Te300
*CANADA* LEADING THE WORLD IN BEING JUST NORTH OF THE UNITED STATES.
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Post by SS109 »

Question on the Kips valve... should I replace the "valve collars" part 92143A (92143-1147) as listed on the Ron Ayers microfiche, as a precautionary measure? I'm sure they wear, right?
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Post by Indawoods »

I sure would!
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Post by Mr. Wibbens »

I wouldn't worry about it and didn't
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Post by BobbyZ »

>|<>QBB<
kdxquebec wrote:The first cut is the deepest, baby I know :wah:
thats why after i do a resto/rebuild on a bike I'll be riding hard,I walk it out of the garage and drop it :partyman: get it out of the way early.Otherwise I'll be worried about it the whole time I'm riding and chances are good I'll end up wadding it up real good :supz:

Good luck on the rebuild I just got back to working on my 93 tonight.
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Post by michael »

Atleast check them for wear,(measure clearance) considering the size of them they needs to be snug. Ya don't want them kips stripping out....
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Post by rbates9 »

>|<>QBB<
BobbyZ wrote:>|<>QBB<
kdxquebec wrote:The first cut is the deepest, baby I know :wah:
thats why after i do a resto/rebuild on a bike I'll be riding hard,I walk it out of the garage and drop it :partyman: get it out of the way early.Otherwise I'll be worried about it the whole time I'm riding and chances are good I'll end up wadding it up real good :supz:

Good luck on the rebuild I just got back to working on my 93 tonight.
+1
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Post by SS109 »

Got my forks and shock back today. Complete rebuild on the shock and new seals and re-valve on the forks, $300. Donny (ZR1) is one fast guy! :prayer:

Waiting on my Dyna-Ring to arrive and then the engine comes apart! :supz:
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Post by kdxquebec »

>|<>QBB<
SS109 wrote:Got my forks and shock back today. Complete rebuild on the shock and new seals and re-valve on the forks, $300.:
Fair price :supz:
'89 KDX 198cc '03 Gasgas Ec250 '13 Husaberg Te300
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Post by SS109 »

Just a pic of my forks and shock and one of my brand new Trail Tech vector w/switch.

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Vector and switch.jpg
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Post by SS109 »

Still waiting on parts. My Hot Rod rod kit came yesterday at least.

Couldn't stand having the suspension ready to rock and not riding. I slapped everything back together Friday night and rode it Saturday to try to tune it a bit. Wow, what a difference! The forks and shock soaked up everything! Washboard, whoops, boulders (OK, cantaloupe sized rocks!), and jumps. I really wish I could have done this sooner as it has made such a dramatic difference that I'm going to have to relearn how to ride my bike! Man, I can carry more speed in turns and a helluva lot more in the whoops. Simply, awesome! Donny at ZR1 rocks! :supz:
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Post by SS109 »

A few more parts have trickled in...

A set of Motoz Enduro ST tires. Note the "wet-or-dry" guide molded into the rear tire in the third pic! I will install them in the "sunny" direction! :mrgreen: I have read a lot of good things about these and can't wait to try them out.

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My $125 special WER damper. Just need the bracket as it is in great shape!

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RK x-ring chain, Renthal CS/Primary Drive sprockets

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Some wheel parts. Not everything has arrived for them yet!

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Post by Mr. Wibbens »

Good buy on the WER, I got mine cheap too

I'd hate to pay for a new one :wink:
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Post by SS109 »

Going to try out some Tusk handlebars. YZ/WR bend. I have always used Renthals but the price on these are great. We will see how they hold up.

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This will give you a big hint on what direction I'm going for looks wise.

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I can't take pics of my Wiseco piston as it is already boxed up to be shipped to Jet-Hot for coating.
Last edited by SS109 on 12:20 am Feb 09 2011, edited 2 times in total.
Youtube Channel: WildAzzRacing
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Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
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