Getting ye olde KDX200 road legal

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Getting ye olde KDX200 road legal

Postby Knightmayre » 09:40 pm Jan 31 2018

Quick Recap,

I have bought myself what the PO told me was a 1991 model but the VIN and ADR (Australian Design Rules) plate came back to Oct 1990.
I checked up with our version of DMV (Vic Roads) yesterday and spoke to a guy in compliance.
He verified that both the VIN and the ADR plate were genuine but also said that it's never been registered in Australia.
As far as I am aware I need a headlight (hi/lo), tail light, brake light, right hand mirror, speedo, horn, quiet exhaust (mine is ridiculously loud) indicators and road legal tyres. I have the headlight which works, but only one setting.
I have the rear light which isn't hooked up yet as are the brake light switches.

If it didn't have the ADR plate then I would have snowballs hell in chance of getting road legal registration.
So now the bug has bitten me, I want to be able to zoom down the road all nice and legal HA!

Issues I am facing with more to come:
(a) The KIPS plate on mine has a breather tube and I initially thought it was sputtering oil out of it but it looks like it's actually where the exhaust joins the manifold. Jason: you mentioned o-rings, can you clarify that for me, I would have assumed that they would melt?? My spare 93 engine also has the KIPS plate but no breather. Hmm.

Choke doo-dah-
(b) I can pull it up (I will post pics soon, I am on my laptop right now) but when I push it down it doesn't go all the way down, sticks up maybe 6mm-ish and that's it.

Idling issue:
(c) I got a copy online which shows the air control screw and an idle screw- all I have is the airscrew, the idle screen appears to be either plugged or non-existant. I have to keep a very light touch on the throttle to keep her idling or just blip it. She starts reasonably well, just kinda pump the kickstarter a couple of times then braaaaaap off she goes.

Finally, can someone tell me what the model I have is, I've seen H- and E- series but I don't know what mine is.

Thank you all for reading this novella :boogie: I hope it's in the correct section!

Dave
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Re: Getting ye olde KDX200 road legal

Postby Knightmayre » 10:36 pm Jan 31 2018

EDIT: Original pics aren't of any use... the pic below actually shows IDLE ADJUST so maybe I should have played with that *smh*
I only noticed it now!

Image

Cheers
Dave
Last edited by Knightmayre on 04:27 am Feb 01 2018, edited 1 time in total.
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Re: Getting ye olde KDX200 road legal

Postby bufftester » 12:19 am Feb 01 2018

As for the carb, it appears to be a Keihin PJ, not the PWK we had here in the states. The idle adjust screw is also the choke valve. If you turn it you will adjust your idle speed. On the PJs it doesn't go all the way down because of this. Tuning it is the same, just use the choke knob where it says adjust idle screw. IMO the PJ carbs are crap, finicky to adjust and they tend to go out of adjustment rather easily. My RMX250 came with one and the first thing I did was dump it for a PWK! lol

As for the model, if its a 90 or 91 then it would be either an "E" (the dirt only version) or an SR (we didn't get the SRs here in the states). Does it have a steel tank or plastic one? The E will have plastic. Another way to tell is to look at the subframe supports. If there are mounts for passenger pegs its likely an SR. Looking at the wiring coming out of your stator I'd guess SR. The E had only 3 wires there (black, white/red, and yellow)
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Re: Getting ye olde KDX200 road legal

Postby Jason » 12:49 am Feb 01 2018

In the USA, a bike made in October would be a next year's model, like 1991.

Post a frame number / VIN and engine number.

The engine number is on the top of the right crankcase half, by the kickstarter OR... under the engine, on the left crankcase half. One would tilt the bike to the right or get down real low to face the bike from the left side. It is under the engine.

Maybe you have an F model.

I'd be happy to have a vented power valve cover. My KX250 and YZ250 have them. They do drip after riding. I just put a folded paper towel under them to catch it.


I was referring to where the exhaust pipe meets the cylinder.

I can't see the pictures, since they are on photobucket, and I am on a cell phone.
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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Getting ye olde KDX200 road legal

Postby Knightmayre » 01:11 am Feb 01 2018

Must be an SR model then as she has a steel petrol tank.
Wouldn't fancy being a pillion... Back in the day I had a road registered IT250, everything on it ssid Not for highway use, but I had papers for in (in the UK).... I attached pegs to the swingarm and took my girlfriend for a spin but every time the power valve opened she almost fell off, much to my dismay as I got punched once she regained her balance.
Anyways sorry for waffling on, can you confirm that I wind in the air screw and back it out 2.5 turns? It seems fairly loose, I have small screw loctite, would you recommend I use that?

Now with the choke/ idle thing do I warm up the bike with it pulled out, then push it down and start twisting it to get it to idle? Can you please give me some more directions?

I have a whole heap of wires inside the bike, I've forgotten what I knew about stators and magnetos.(I have an avionics background but that was ages ago).
I am assuming that there would be some kind of bridge rectifier in there somewhe, never seen AC powered indicator relays before.

Again, thank you for all the help and pointers, much appreciated!
Cheers
Dave
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Re: Getting ye olde KDX200 road legal

Postby Knightmayre » 01:24 am Feb 01 2018

I'll repost the pics later on from my server rather than photobucket.
I did find the engine number but it's pretty much illegible...
VIN is JKADXNF15LA001261, ADR compliance plate is dated 10/1990 7840

For some reason every bike wreckers I call laugh when I ask if they have a speedo for it :mrgreen:

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Re: Getting ye olde KDX200 road legal

Postby Jason » 03:11 am Feb 01 2018

JKADXNF15LA001261

The "F" means "F" model. The "L" means 1990.

Can you post a picture of the motorcycle??

I am off the cell phone now and on the home computer. I can see the pics now.

That does look like a PJ carb. I don't know what was stock in AUS, but as mentioned we had PWK here from 1988 on.

Can you clean off the engine number??

Decoded VIN:
Destination Market:
Worldwide
Make:
KAWASAKI
Manufacturer Name:
KAWASAKI MOTORS CORP., U.S.A.
Model Year:
1990
Plant City:
Akashi
Vehicle Type:
MOTORCYCLE
Plant Country:
Japan
Plant Company Name:
Kawasaki Heavy Ind., LTD
Plant State:
Hyogo
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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Re: Getting ye olde KDX200 road legal

Postby Jason » 03:12 am Feb 01 2018

It is a KDX200-F2. EDIT: My best guess.

When searching around, apparently adding "ADR" makes more things pop up. One AUS retailer showed ADR from 1989 - 1991.

From http://www.dirtbikeworld.net ...

"There's an ADR-complianced "F" model with a steel petrol tank, and the non-complianced enduro "E" version - if you want to rego it, then make sure its an F."

perthstreetbikes.com ...
"Back in 1990 there was the KDX200E and KDX200F. The E can NOT be road licenced. The F was the road licenced model.

It was a stupid idea that frustrated plenty of people at the time. The E was an exceptionally good enduro bike but was limited in use because of the lack of registration. The F had ADR compliance but wasn't as good off-road."

Yes, there were "E", "F" and "G" models. How else did 1995 get to be the "H" model? :lol: :mrgreen: :razz:
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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Getting ye olde KDX200 road legal

Postby Knightmayre » 05:33 am Feb 01 2018

Has taken me ages to get this working, but here we go...

Engine Number:

Image

Some shots of the old girl, getting dark so sorry about the quality:

Image

Image

Image

Cheers
Dave
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Re: Getting ye olde KDX200 road legal

Postby Jason » 06:37 am Feb 01 2018

From the VIN, it is a 1990 F model.

From the engine number, it is from an F or G model.

NOT from an "E" are:
the left rear sub-pipe
metal tank
metal under rear fender

I can see from the Model Identification Guide that the G came with mirrors and apparently blinkers.

Where does the hose by the choke go, a 2-stroke oil tank maybe??

Sorry to not give more answers. The USA never got KDX200 B, D, F or G models or KDX220B models. (or 1995 KDX250) (or KDX125) (or KDX220-A before 1997) (oe SR any version)

The left sub-pipe had a rear footpeg there. The metal on the back is probably for the tag holder.

I think someone stripped the less dirt friendly parts off.
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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Re: Getting ye olde KDX200 road legal

Postby bufftester » 04:27 pm Feb 01 2018

Yeah, definitely an SR. The tabs on the subframe spars are for the pillion pegs. The tube on the carb is a vent, should be matching one on the other side. IIRC the oil injection is a separate pump that is mounted on the case somewhere and pumps through a check valve, no oil goes through the carb.

For idle, yes, pull the choke to warm up, once warm push it back down and turn the knob to set idle speed. As Jason said, lots of the other metal bits are for street legal requirement items (tag, indicators, etc). Good luck , she appears to be in very decnet shape for an old SR!
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Re: Getting ye olde KDX200 road legal

Postby Jason » 05:35 pm Feb 01 2018

Something is not right. I looked at the pictures of the F closer up, and it looks like an "E". Yours looks like a "G" more than an "F". Can you post some pictures of the right side, the handlebars as seen from above... steering lock?

SR 1990 had USD forks.

Do you have rear footpeg tabs on the right of the bike? I do see them for the bar and pegs on the left.
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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Getting ye olde KDX200 road legal

Postby Knightmayre » 07:48 pm Feb 01 2018

Hi again

Here's some more pics for you... Ive kept them large for clarity...

ADR plates:

Image

Right side and handlebar pics:

Image

Image

Image

Image

Thanks again
Dave
Last edited by Knightmayre on 10:54 pm Feb 01 2018, edited 1 time in total.
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Re: Getting ye olde KDX200 road legal

Postby bufftester » 09:17 pm Feb 01 2018

Well the plate says F model anyways! lol. The more I think about it and look, I don't think the SRs had an oil tank and pump but were pre mix bikes as well. As we've said, never got them in the states so most of my info comes from shoddy memory of half listened to conversations :partyman: Regardless, she looks good and you should have a proper good time getting her dirty. Dragonfly (member on here) has a bunch of SR infor HERE.
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Re: Getting ye olde KDX200 road legal

Postby Jason » 02:41 am Feb 02 2018

Thank you for the pictures.

What is the white thing with apparently cut wires on the right side, above the radiator, on the frame?

What is the metal tab below the tab for the brake reservoir?

I can tell that the frame is painted. Does it look like there are any footpeg mounting brackets ground off the frame on the right side?

This bike confuses me. From what I see in the model identification guide, there are no rear footpegs on an "F", but are on a "G". Is there a chance someone put a "G" subpipe on the left rear of the frame?

https://www.youtube.com/v/rSxAfynNRXY

There's a video from AUS. Do you think yours had the metal bars under the rear fender?

Shouldn't an "F" not have those metal bars??

I am just confused, but I am seeing a lot of stuff that looks like "G" stuff, not "F" stuff.
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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Re: Getting ye olde KDX200 road legal

Postby Jason » 03:11 am Feb 02 2018

Do your clutch and front brake lever mounts have holes for mirrors?
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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Re: Getting ye olde KDX200 road legal

Postby Knightmayre » 04:02 am Feb 02 2018

There is a mount for a mirror on the right hand side, and mounts for indicators. Don't know about the rest of the stuff you mentioned in the previous post but is getting a bit dark and she's decided to pop her left hand radiator. I did manage to get it idling nicely about 5 mins before she started barfing coolant. Can see it was a crappy repair job *sadface*
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Re: Getting ye olde KDX200 road legal

Postby Jason » 04:45 am Feb 02 2018

If I were you, I would try to find some online parts microfiche in AUS that showed "F" and "G" models. I don't see any mirrors on the F pictures.

At the farthest extreme of thinking, do you think it is a "G" with a counterfeit plate? JUST asking a wild, out there question.

EDIT:

NEVERMIND. I am looking on gumtree now. ALL kinds of goofy looking KDX's. :razz:
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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Re: Getting ye olde KDX200 road legal

Postby Knightmayre » 04:57 am Feb 02 2018

The guy I spoke to at Vic Roads confirmed that although the bike has never been registered to go on dirt or tarmac it has been verified by federal government in Canberra that the ADR plate and VIN numbers match. All they (Vic Roads) care about is that the VIN number matches engine number and it has the appropriate ADR plate, that would be a lot of counterfeiting just to get a dirt bike on the road.
Mind you I dunno what a G model is :)
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Re: Getting ye olde KDX200 road legal

Postby Jason » 05:01 am Feb 02 2018

I think I finally figured it out. Someone stripped down a "G" to make it into an "F". Sadly, it was Kawasaki!! :razz:

Did Australia even have the "E" model with a plastic tank?
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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