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Restore

Posted: 06:25 pm Feb 01 2017
by MaverickAus
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
Garry

Restore

Posted: 07:18 pm Feb 01 2017
by doakley
Battery? What battery? Don't tell me you have e-start on a kdx, 'cause if you do you've got my perfect bike!

Re: Restore

Posted: 07:29 pm Feb 01 2017
by MaverickAus
Sorry been a while lol I guess I was thinking about my KLX when I said battery

Re: Restore

Posted: 07:49 pm Feb 01 2017
by s10gto
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!

Re: Restore

Posted: 07:53 pm Feb 01 2017
by pumpguy
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.

Re: Restore

Posted: 07:55 pm Feb 01 2017
by MaverickAus
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.

Re: Restore

Posted: 10:00 pm Feb 01 2017
by doctord23
Air filter; fresh fuel; clean the carb; grease the suspension.

Restore

Posted: 11:17 pm Feb 01 2017
by MaverickAus
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

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

Image

Restore

Posted: 06:03 am Feb 02 2017
by MaverickAus
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).

Re: Restore

Posted: 03:59 pm Feb 02 2017
by bufftester
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.

Re: Restore

Posted: 10:44 pm Feb 02 2017
by MaverickAus
Thank you, since I wrote the above post I read on another forum truck bedliner was durable and if clear coated looked ok.

Re: Restore

Posted: 11:00 pm Feb 02 2017
by MaverickAus
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?

Restore

Posted: 12:33 am Feb 03 2017
by MaverickAus
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.

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

Restore

Posted: 04:02 am Feb 04 2017
by MaverickAus
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.
Latest photo

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Restore

Posted: 10:32 am Feb 04 2017
by Dekon
Is that an SR? I noticed the key and horn.

Restore

Posted: 02:26 pm Feb 04 2017
by MaverickAus
No idea, please enlighten me.

Re: Restore

Posted: 02:40 pm Feb 04 2017
by KDXGarage
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.

Restore

Posted: 05:37 pm Feb 04 2017
by MaverickAus
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

Restore

Posted: 07:24 pm Feb 04 2017
by JL4049
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?

Re: Restore

Posted: 07:51 pm Feb 04 2017
by KDXGarage
Well, there ya go. Thanks.