My thread (2000 KDX 200 rebuild)

canuckhybrid125 · Post by **canuckhybrid125** » 07:41 pm Sep 16 2010

Did they plug and tape off all the holes where bolts go before powdercoating your frame and swingarm?

bmiller · Post by **bmiller** » 07:52 pm Sep 16 2010

canuckhybrid125 wrote:Did they plug and tape off all the holes where bolts go before powdercoating your frame and swingarm?

yep. threads, bearing seats, speed clip holder thingy,...

canuckhybrid125 · Post by **canuckhybrid125** » 08:15 pm Sep 16 2010

bmiller wrote:
canuckhybrid125 wrote:Did they plug and tape off all the holes where bolts go before powdercoating your frame and swingarm?

yep. threads, bearing seats, speed clip holder thingy,...

Good they missed 2or3 on mine and I had to retap.

bmiller · Post by **bmiller** » 04:49 pm Sep 22 2010

OEM parts have arrived. A little scary...

See wiki for updated pictures.

http://www.phospher.com/index.php/2000_KDX_200

heckler · Post by **heckler** » 02:21 pm Sep 23 2010

nice paint job! Looks great.

Is the KX500 stem the same as the KDX? Does it look like a straight swap as expected?

bmiller · Post by **bmiller** » 03:30 pm Sep 23 2010

It appears the KX500 stem is exactly the same. I'll be pressing bearings on and off this weekend. I'll take pictures and report my progress.

bmiller · Post by **bmiller** » 09:31 pm Sep 25 2010

Update: Installed a bunch of bearings/races, seals, triple clamps and greased up.

http://www.phospher.com/index.php/2000_KDX_200

bigerestblazer · Post by **bigerestblazer** » 06:32 pm Sep 26 2010

looking great and i Love the special tool!! lol i have about 20 different sizes of those laying around just because i had to make a bearing go in and dont have a driver kit. keep up the good work your on the downhill slide now it looks like.

David_L6 · Post by **David_L6** » 07:02 pm Sep 26 2010

Good job.

Thanks for taking the time to take and post all the pictures. They will be a lot of help to those of us that do in the future what you are doing now.

bmiller · Post by **bmiller** » 10:44 pm Sep 26 2010

So far so good. I'm having a great time doing it. The press has really made things so much easier.

When I'm "done" I'll post everything that's on my wiki in this thread to hopefully create more keywords for others searching with questions that I may have answered.

I hope the KDX is as fun as I remembered in 2005 :)

heckler · Post by **heckler** » 12:31 am Sep 27 2010

yeah, that lower shock bearing is a pain in the butt. I had our machinist make a tool for me to press it out with.

bmiller · Post by **bmiller** » 08:22 pm Oct 01 2010

Got my top-end back from Eric Gorr. I just hope he'll refund money.

The worst job I've ever seen...

http://www.phospher.com/index.php/2000_KDX_200

Post by **scheckaet** » 09:12 pm Oct 01 2010

u sure u got YOUR cylinder back?

bmiller · Post by **bmiller** » 09:15 pm Oct 01 2010

scheckaet wrote:u sure u got YOUR cylinder back?

I am 100% positive it's not the one I sent him.

Post by **Indawoods** » 10:30 pm Oct 01 2010

Another case of he got too big for his britches....

Coop · Post by **Coop** » 09:41 am Oct 02 2010

Sounds to me like you got a cylinder someone sent in for repair sent to you by mistake. I've talked with Eric quite a bit in the past and I would really be surprised if that was intentionally sent to you that way.

bmiller · Post by **bmiller** » 09:55 am Oct 02 2010

Coop wrote:Sounds to me like you got a cylinder someone sent in for repair sent to you by mistake. I've talked with Eric quite a bit in the past and I would really be surprised if that was intentionally sent to you that way.

I'll give him a call on Monday. It is bored to 225cc which is what I requested. Do you guys think a head gasket will seal that pitted deck?

Tomm9050 · Post by **Tomm9050** » 12:54 pm Oct 02 2010

Try RB designs / great work on my head.

http://www.rb-designs.com/

bmiller · Post by **bmiller** » 01:09 pm Oct 02 2010

Tomm9050 wrote:Try RB designs / great work on my head.

http://www.rb-designs.com/

I was considering sending my carb to RB for their famous modification. The machine work done by Eric looks legit. I'll post an update after I talk to him.

bmiller · Post by **bmiller** » 03:25 pm Oct 04 2010

I just got off of the phone with Eric.

He seemed real nonchalant about the condition of the cylinder. He said the pitting is normal after an acid wash and he recommends just using a little sealant. He also said Kawasaki's material is '****' which is why he always helicoils the threads. He missed a few threads which were damaged and I'll have to do them myself.

He also said the damaged/stripped cylinder plugs where like that when he got it and he had a hard time removing them.

Also, he did send me a different cylinder. My cylinder had a sleeve installed and couldn't be bored to 225. So,... it explains a lot.

I'm not sure how I feel about the whole situation.

Is 225cc worth the pitting and helicoils? I'm feeling it is,.. what do you guys think?

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My thread (2000 KDX 200 rebuild)

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