KDXRIDER.NET

Hey guys
i've decided to keep an online diary, i mean, build thread, on my recently aquired 96 KDX 200 project bike
rather then having a dozen different posts about it everytime i have a question im just going to keep it all in here

i found this bike for 400 dollars on craigslist
the story went the first owner owed the guy i bought it from some money and he gave him the bike to settle the bill
it was recently rebuild and had been sitting for 2 years

now, it wouldnt start, thought if you spayed started fluid in it it would run for a few seconds

i was hoping the bike was fine when it last changed owners and had sat with premix in the carb for the last 2 years and that was the problem
easy fix, i figured, turn around and sell it for double what i paid for it

well, no such luck
when i got it home and started stripping some parts off it i noticed there were a few things worng with the bike

so far i have noticed the following flaws:
inner clutch cover broken
KIPS actuator governor broken
piston shot
cylinder in need of replating
intake booth broken
rear brake reservoir mounting tab broken
rear master cylinder gaurd missing
rear tire woudnt hold air
one rear spoke missing
no headlight/numberplate

i have bought a used inner clutch cover
a new kips actuator governor
new intake booth
used rear master cylinder gaurd
new rear spoke
and the acompanying gaskets

the gaskets and governor should be in tomorrow so then i will put the inner and out clutch covers back together
i have allready played with the piston and i got the rings to free up again
once all that is put back together i will put the engine back in the frame and see if it might run (though i doubt it) with the louzy piston and cilynder)

money for a new top end probably wont come around untill Christmass

this is me and the boy when we went to pick the bike up



the damaged inner clutch cover


the damaged governor



the damaged piston




to make matter even worse i took a nasty spill on my daily driver KDX and i had to scavenge some front end parts off this project bike to make up for the damage, so now it is also missing the handlebars and the clutch perch

ill post a shot of the bike as it sits later to show the backwards progress ive made

i did manage to stop by my local car tire guys and they had a look at the rear inner
they installed a new valve and she is good as now, as soon as i get the new spoke installed i will put the rear tire back on :)



(and finally a list of links to all the posts related to this rebuild)
http://kdxrider.net/forums/viewtopic.ph ... 20#p117620
http://kdxrider.net/forums/viewtopic.ph ... 07#p117807
http://kdxrider.net/forums/viewtopic.ph ... 14#p117814
http://kdxrider.net/forums/viewtopic.ph ... 00#p118400
http://kdxrider.net/forums/viewtopic.ph ... 89#p118489

and here a shot of how she sits today
(depressing isnt it)

funny story...sounds about just like mine

scheckaet wrote:funny story...sounds about just like mine

yes, but i ended up buying a inner clutch cover

its been a long road but i just send the cylinder out to langcourt earlier this week

in the mean time i replaced the inner clutch cover aswell as the KIPS governor
i also added one rear spoke (it was missing one) and fixed the inner tube so it now holds air

the front forks look like they are leaking so ill just swap both forks out for the ones from my daily driver KDX
(i put a KX front end on there a while ago)

other then a good cleaning and a new set of of sprockets i think she'll be ready to go as soon as the cylinder gets back

got the engine put back together and fired her up today
i must say, she is a BEAST
i dont know if it is the gearing on this ride, the 2 MM overbore, the full FMF exhaust, the boysen reeds or a combination of all
iether way, once i feel secure about the tranny in this bike (and the entire bottom end i guess) im thinking of swapping it into my daily driver bike and selling the engine thats in there now with this bike


there are still a few little things to look at but the end is definatly in sight :)

figured i would post some pics of this baby
we went from this



to this





i bought a new KLX style headlight for my DD KDX so i got to hand the stock unit down to this bike

the only things left to button up is a new chain, hooking up the radiator overflow and getting the carb dialed in
(she runs real strong but will not start without some spray)

thanks to Greg (bufftester) all that is purple will be replaces with black (seat) and green (tank, shrouds) to give her a more updated look

newer parts came in today :)

Looks great, glad I could help out the 'lil sister'.

Looking good for sure......sorry not a fan of the purple but that looks great!

thanks guys

the purple has a certain flair of its own and i like it on my daily driver but i am glad i could update the look of this bike

good effort! the black/green make it look much newer!

thank UK, thats exactly what i hoped to achieve with it
funny what a big difference that makes

She looks great...