Restore

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Restore

Postby MaverickAus » 06:25 pm Feb 01 2017

Hi Guys,
I have a 1999 KDX200 which has not been run for about 5 or 6 years. It's time for me to get it running again so I'm asking for suggestions as to what to check before I try to start it again. It was running fine and I know I'll need to change the fuel, coolant and oil. Should I check the power valve to see if it's stuck? Will it start with a flat / stuffed battery?
Any suggestions appreciated.
Thanks in advance
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Restore

Postby doakley » 07:18 pm Feb 01 2017

Battery? What battery? Don't tell me you have e-start on a kdx, 'cause if you do you've got my perfect bike!
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Re: Restore

Postby MaverickAus » 07:29 pm Feb 01 2017

Sorry been a while lol I guess I was thinking about my KLX when I said battery
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Re: Restore

Postby s10gto » 07:49 pm Feb 01 2017

Fresh fuel and check the air filter. She will most likely start right up. After she warms up I would change all other fluids.

I bought my 05 220 in 2013. It was in storage since 2006. Started right up!
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Re: Restore

Postby pumpguy » 07:53 pm Feb 01 2017

MaverickAus wrote:Sorry been a while lol I guess I was thinking about my KLX when I said battery



Yeah!, that's what I want. E start on my KDX.
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Re: Restore

Postby MaverickAus » 07:55 pm Feb 01 2017

Thanks s10gto yes of course the air filter may be deteriorated. I have a new one ready to fit. Just have to find my filter oil, it's been a while since I used it.
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Re: Restore

Postby doctord23 » 10:00 pm Feb 01 2017

Air filter; fresh fuel; clean the carb; grease the suspension.
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Restore

Postby MaverickAus » 11:17 pm Feb 01 2017

Got the bike up on the stand and looked it over the frame is missing lots of paint and I'd say the suspension and all the moving parts need some loving so I decided to do a complete teardown and strip back the frame and paint it. This will be a first for me but the KDX is pretty simple so I'm giving it a go. I'll also get the suspension redone for my weight with fresh oil and gas (rear)

Anyway here is the before photo

Image

And where I'm up to before it got too hot in the garage.

Image
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Postby MaverickAus » 06:03 am Feb 02 2017

Any suggestions for a paint for the frame? Not so much brands but what type? I'm in Australia so a lot of the brands you guys get in America are not available here or are too expensive to import.
Many years ago a mate painted his GPz1100 frame with 2 part epoxy which was tough and looked great but a bit fragile (chipped easily).
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Re: Restore

Postby bufftester » 03:59 pm Feb 02 2017

Most durable is going to be powder coat. Don't know about Oz but where I'm at it's about a $300 job and a wait since most of the powder coat guys in my area are always busy with the car guys. When I did my hybrid I used rattle can engine paint with a clear coat cover. Not nearly as durable, but cheap and easy to touch up when needed.
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Re: Restore

Postby MaverickAus » 10:44 pm Feb 02 2017

Thank you, since I wrote the above post I read on another forum truck bedliner was durable and if clear coated looked ok.
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Re: Restore

Postby MaverickAus » 11:00 pm Feb 02 2017

Does anyone know how to tell what springs are in the forks just by looking at them? Do they have numbers stamped on them or some identifying marks?
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Restore

Postby MaverickAus » 12:33 am Feb 03 2017

Didn't get time to do anything this morning, family duties, did a little bit this afternoon I think these need replacing.

Image

Got to this stage, I have to take some off the front then some off the back etc otherwise it wanst to fall off the stand. I took the boat anchor (muffler) off and the bike fell forward, fortunately slowly and I was able to catch it. I think I'll have to clamp it to the stand.

Image

The garage got too hot and that drove me back into the air conditioning
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Restore

Postby MaverickAus » 04:02 am Feb 04 2017

Getting there slowly the air box and shock were a bit of a bitch but finally got them out. The swingarm bolt won't come out left it soaking overnight with WD-40 hopefully it comes out tomorrow. It not seized I can rotate it
Got onto a local bloke who will strip down the frame and swingarm for $100 I think I'll get him to do it instead of taking hours and making lots of dust if I do it.
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Postby Dekon » 10:32 am Feb 04 2017

Is that an SR? I noticed the key and horn.
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Restore

Postby MaverickAus » 02:26 pm Feb 04 2017

No idea, please enlighten me.
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Re: Restore

Postby Jason » 02:40 pm Feb 04 2017

Please post a frame number.

AUS got street legal versions and dirt only versions, I think. I am assuming this was the street legal version, as someone may have added a horn, but no way in hell they added a key switch and steering lock.

Thank you.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Restore

Postby MaverickAus » 05:37 pm Feb 04 2017

Jason wrote:Please post a frame number.


Image

AUS got street legal versions and dirt only versions, I think. I am assuming this was the street legal version, as someone may have added a horn, but no way in hell they added a key switch and steering lock.

Thank you.


It came with all the road gear in a box

Image
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Postby JL4049 » 07:24 pm Feb 04 2017

Mine is the same model, the Aus ones are similar to the US 'H' models however on the Kawasaki parts fiches are listed as 'J' model. They are able to be street registered but mechanically are the same as an H model, wiring is almost as for the SR model with the exception of the low oil light as there is no oil tank.
Lighting circuits are DC and voltage is regulated. Just noticed your headlight is a different shape to mine, maybe off an earlier model?
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Re: Restore

Postby Jason » 07:51 pm Feb 04 2017

Well, there ya go. Thanks.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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