My thread (2000 KDX 200 rebuild)

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bmiller
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Post by bmiller »

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David_L6 wrote:Be careful with all that black plastic. You're going to make that Kawasaki look like a Honda :shock: or something. :mrgreen:


I'm just kidding. Your bike looks great. Thanks for taking the time to take and post all the pictures and video.

:) I'll always have a touch of green in there somewhere.
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rbates9
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Post by rbates9 »

Kawi makes Black "Works" bikes too. And I would appreciate it if you wouldn't use the H word on this site, there are younger members ya know. :lol:
bmiller
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Post by bmiller »

I went riding today for about 4 hours. It ran beautifully with much more power than the bike has ever made. The 225cc kit was well worth it.

I had one problem--one of the head studs leaks coolant. I ensured all nuts were torqued correctly and it still leaked--just the one stud/nut.

I'm riding tomorrow as well at Hollister CA so I removed the head, replaced the gasket with a brand-new OEM one and put a liberal amount of Indian Head Shellac on both sides of the gasket this time. When I assembled the engine I only used RTV on the pitted cylinder side.


Do the head studs penetrate the water jackets?


If you're not familiar with Indian Head is--this stuff is tough and is a serious pain to remove.

Link to Indian Head: http://www.amazon.com/Permatex-20539-In ... B0008KLOG6


The bike is all back together and I'll be riding it tomorrow.

Any thoughts?
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Mr. Wibbens
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Post by Mr. Wibbens »

I am the original owner of a 2000 Kawasaki KDX 200. I rode the bike for roughly 5 years, probably no more than 300 miles total. It has been sitting since 2006.

So why'd it have a sleeve in it?? Motor barely had any hours on it :?
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bmiller
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Post by bmiller »

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Mr. Wibbens wrote:I am the original owner of a 2000 Kawasaki KDX 200. I rode the bike for roughly 5 years, probably no more than 300 miles total. It has been sitting since 2006.

So why'd it have a sleeve in it?? Motor barely had any hours on it :?
Dropped the bike in a river, pulled the top-end and it was destroyed. I sent the cylinder off to LA Sleeve and they "insisted" it needed to be sleeved. Big mistake.
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Post by Mr. Wibbens »

Well I think that's kinda what they do :wink:
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KDX4ID
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Post by KDX4ID »

bmiller... great job on the bike it looks awesome!

Your attention to detail is tops!
CURRENT FLEET
2008 KTM 990 Adventure...Alaska here I come!
2010 KTM 300 XCW... stop me before I buy again!
2005 KDX220... single track sweetie
2007 KTM 450 EXC... my baby
2008 KTM Superduke... Canyon Carver
1996 Honda 650L... GONE but not forgotten
http://www.friendsoftruckeetrails.org
bmiller
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Post by bmiller »

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KDX4ID wrote:bmiller... great job on the bike it looks awesome!

Your attention to detail is tops!

Thanks, it took a lot of time... :mrgreen:
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Post by saldanaracing »

Great Job. Your bike looks awesome. how much did this project cost you? I am considering rebuilding my 2002 220R.
bmiller
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Post by bmiller »

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saldanaracing wrote:Great Job. Your bike looks awesome. how much did this project cost you? I am considering rebuilding my 2002 220R.
I'd rather not count :)........

$250 for the forks
$200 for the powder coat job
$300 for the OEM replacement parts
$800 for the aftermarket parts
$420 for the 225cc big bore kit and cylinder plating
add a few more hundred in for miscellaneous parts, oil, plugs, grease, fuel, hydraulic press etc...


This is the bulk of it. Labor was all me and a few friends.

I'd still like to do the RB carb mod..


The same weekend I rode my 'new' KDX I also road my friend's 2006 KTM 300exc (insane 2-stroke). While the KTM was super plush and amazing--there's nothing like the feel of my KDX. The KDX just fits really well. And man.. those 2001 KX500 forks are awesome!
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Post by gregp »

I owned a '98 KTM300EXC, and spent a lot of quality time with an '01 300 EXC...and I am now riding my 2nd H series KDX. That should tell you something. The KDX's are *Great* trail machines, and really tough to beat in terms of performance, comfort, and reliability.
Your bike looks great!
2004 Dual Sported KDX200
1999 Ninja 250 (Daughter's)
1996 DR 650 (stock, mostly street use)
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