Complete rebuild/restoration?

Greenbandit200 · Post by **Greenbandit200** » 03:10 pm Aug 22 2018

I'm having a hard time finding the complete rebuild kit is one available that anybody knows of or do I have to piece mail all this together? it's going to be a complete restoration for a 97 kdx200 the bike was abused very badly. I had one when I was younger and I'm glad to have one again just having a hard time finding a complete kit that will work. I am sending the top end in carb to RB for mods and while it's there I would love to do the bottom in myself any suggestions? Thanks for the help guys look forward to seeing all your replies.

ericr · Post by **ericr** » 05:16 pm Aug 22 2018

If you're asking whether a complete engine rebuild kit exists, the answer is no. You'll have to piece it together yourself.

I went through a restoration a few months ago. Here's a link to the page that describes the items that went into the engine rebuild... http://www.kdxrider.net/forums/viewtopi ... 6&start=60

Your first step should be to get a copy of the manual and study the sections related to engine removal and disassembly. There's also a couple videos by Sparkingdogg on youtube that show the entire process... https://tinyurl.com/yc3fcz69

When you're ready, you can start ordering parts. I have found OEM parts to be best priced from Partzilla.com provided that you can order their minimum for free shipping. RockymountainATV also has OEM parts that cost a bit more but have lower cost shipping for small orders.

I'd hold off on the OEM parts orders until you've disassembled the engine and measured items for wear. This includes bearings, besides the main crank bearings, OEM clutch springs, shift drum and shift forks, countershaft circlip, OEM clutch and throttle cables, etc.

When measuring, use a bore gauge or pay a machinist to measure the cylinder bore. If worn, I suggest using Milennium for Nikasil replating. Since you're sending items to RB Designs, I'd also suggest sending him your crank along with a rod kit for rebuilding. It's worth the $45.

Overall, it's not that difficult to rebuild these engines. Make sure you do a leakdown test when done. Good luck and have fun!

david · Post by **david** » 07:22 pm Aug 22 2018

We have been told lately that RB is not accepting any more carbs to work on. Says they are getting too old, but he will sell you a new one.

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Post by **KDXGarage** » 10:30 pm Aug 22 2018

There is no KDX aftermarket crankshaft or combination top and bottom end kit. Look for an OEM or aftermarket connecting rod kit or individual OEM parts. Partzilla is my go to place for OEM parts.

6 Riders · Post by **6 Riders** » 11:56 am Aug 23 2018

And most certainly steer clear of the Wiseco cranks, they have a history of being junk.

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Post by **KDXGarage** » 12:03 pm Aug 23 2018

That is a wonderful benefit of Wiseco and Hot Rods not making (well, OK, paying some place in China to make) crankshafts for KDX's.

Greenbandit200 · Post by **Greenbandit200** » 12:44 pm Aug 23 2018

That's good news cuz my previous hobby that I had to give up to take on my new mx rebuilding Hobby, happened to be building high-performance small blocks to compete against Big Blocks in the truck pulls. So needless to say I'm probably, no most definitely going to be building a performance/hybrid bike. So my next question would be do we think RB designs could balance my crank as well as a performance crank if a performance crank is even available?

Post by **KDXGarage** » 01:38 pm Aug 23 2018

What's a performance crank??

What's a performance / hybrid bike??

Look on Crankworks page.

Greenbandit200 · Post by **Greenbandit200** » 02:58 pm Aug 23 2018

Jason wrote:What's a performance crank??

What's a performance / hybrid bike??

Look on Crankworks page.

a performance crank maybe one with tighter tolerances than an oem crank or balance to a higher RPM or better Rockwell to handle more stress. or even a cleaner, smoother, finer finish than that rough cut crap from China maybe, not sure??
A Performance Hybrid. Maybe a showa front end, MX rear fender and get rid of that dorky gooseneck that the KDX is known for. Race fuel, 50 horse, 17.5:1compression ratio, and 100mph. A classic 200 that will eat a 250 for breakfast.

Post by **Molly's 70** » 06:17 pm Aug 23 2018

[quote="Greenbandit200"][quote="Jason"]What's a performance crank??

While Small Block Chevy & Big Block Chevy crankshaft's can be straightened & made lighter & lots of other modifications, our 2 stroke crankshafts are not the same.
A factory crankshaft, rebuilt by a good shop is all I've ever needed.

Post by **KDXGarage** » 06:26 pm Aug 23 2018

I don't think you will be getting 50 horse power from a KDX200.

Stock is about 28.

Good luck and have fun.

david · Post by **david** » 08:23 pm Aug 23 2018

35.5 hp (36PS) according to Kawasaki

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Post by **KDXGarage** » 01:33 am Aug 24 2018

not at the rear wheel, maybe at the countershaft

it's about 30 with a pipe and silencer

35 is about where the YZ125 is

Greenbandit200 · Post by **Greenbandit200** » 12:00 pm Aug 24 2018

I might not quite get 50 hp out of it, but it will be fun to try. Even more fun to ride.lol

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