'96 KDX 200 Piston & Conrod Replacement

[drsmk]

Hi guys !!

I am about to replace piston & conrod on my bike... but i have a simple question.

Many parts from KAWASAKI fits more than one model, and i was wondering if i could use a conrod from a different model (as they seem to be pretty much the same).

The reason why i ask this is because i bought on the internet a conrod kit, but when i got it, on the label it says "88-91 KX".

Will this fit my '96 KDX 200 ???

Thank you for helping me out on this one... ;)

[Julien D]

Not likely. Most conrods for different models are different lengths. As far as I know the H series KDX conrod was only used in KDX200 and 220 95 and up.

[drsmk]

Hi, thanks for your feedback.

However, i kept searching info regarding both conrods, and found the info below:

Application: KX 125
Year:88-91
A:109 mm
B:21 mm
C:29 mm
Weight: 350 g


Application: KDX 200
Year:89-05
A:109 mm
B:21 mm
C:29 mm
Weight: 350 g


Both conrods seem to have the same specifications... to make sure, i think i will have to compare them side by side after taking the old one out...

Thanks anyway for your help ;)

I will keep you informed of the "result" after i have the engine opened :)

Nice greetings.

[Julien D]

Interesting! Make sure and post updates after you get them side by side. Oh, and welcome to KDXRIDER!

Found this, also...

http://www.cheapcycleparts.com/products ... ecting-rod

[drsmk]

just because... here's my pretty baby ;)



I bought it from a friend this summer.... the bike was parked for years.

i cleanned it, got a new chain and transmission kit, new cables and new tires.... and went for a couple of rides.

i'm about to replace the piston and conrod now....

next on the "to buy" list comes the clutch kit :D

step by step i'll give her a new soul :)

i''m loving it ;)

[fuzzy]

Sure, it's a big bore 125 motor, with enhanced KIPS. Pretty much all 200's are big bore brothers to the companies' 125....making a short revving 125 with much more torque.

[adam728]

Both Pro-X and Hot Rods show their part number rods fitting 1989-2006 KDX200, 1997-2006 KDX220, and 1989-1991 KX125.

03.4285 for Pro-X
8129 for Hot Rods

[Slick_Nick]

If you go into the parts diagrams on the Kawasaki website you can click on "other bikes that fit this part" and it will tell you if they're interchangeable. I wouldn't just throw that in there if I wasn't completely sure.

Out of curiosity, why are you replacing the rod? On KDX's the rod shouldn't need to be replaced unless the main bearing is focked, which unless it was run without oil for a LONG time is very unlikely.

[Robkx250]

Yes the kx 125 89 to 91 rod will fit the kdx 200 or the 220 there the same

[drsmk]

hey guys!!

thank you all for your feedback.

The reason why i'm replacing the rod as well is simple: even though i am replacing the piston for a new one with the same size, the bike will get more conpression and i am afraid that the rod doesn't resist.

Maybe most of the you won't agree with me, but i think it's the safest way.

As i said before, i bought the bike this summer and it has been parked for years....

in the future, when i replace the piston again, probably i won't need to change the rod again.

I'll update this topic with some pictures as soon as i have the engine opened.


Nice greetings everyone,

Pedro.

baaaaap!!!! ;)

[adam728]

Despite the durable repuation of the KDX engine, preventative maintenance rebuilding the bottom end is rarely a bad thing. Especially after sitting for years, where minor rusting of the bearings can cause major failure in short order.

Thumbs up on doing it right.

Sent via morse code

[fuzzy]

Too bad they don't make a stroker

[adam728]

Too bad they don't make a stroker

That would require a crank pin location change, not effected by rod length. In sure a custom stroker crank could be done by plenty of places. Gettinh the rest of the engine right would be the issue (porting, squish, intake changes, etc)

Sent via morse code

[Franlr]

You might as well replace all the bearings and seals to while you have the crank case spilt forthe conrod replacement.Just a thought.

[drsmk]

indeed. i didnt say before but together with the piston kit and rod kit i bought a full engine gasket kit, engine oil seals kit and also both main bearings for the crankshaft...

when i said i was giving her a new soul, i really meant it !!! :D

[rbates9]

Too bad they don't make a stroker

I found once a web site that does a KDX 200 - 250 stroker big bore kit. But it was very expensive. (About $5000 if I remember right.) and you sent the complete engine to them. They bored and stroked it, ground out the cases to give a little more room, and did some other stuff. I think it ended up being 25?cc when they were done. I have looked again for the web site with no luck.

[ICRage42]

I found this a while ago when looking for some parts. Not expensive at at really 400 for the kit for yourself or 600 or so for them to do it and put together.

http://rpmmfg.com/KXBigBore.aspx

scroll down a bit for 200 to 240 cc. Not sure of their quality just threw the link in favorites for later.

[drsmk]

Hello KDX Riders !!

My KDX is very close from getting back on the track

During the replacement i found out that the cylinder was not in the desired conditions so I decided that it would be better to have it repaired. I sent it to Langcourt (http://www.langcourt.com). It took about 4 weeks to get it back, but I am really happy with the result. These guys really know what they are doing !!!!

As promised, find below some pictures of the Piston/Conrod Replacement. (btw, regarding my first post's question, the conrod from the 88-91 KX is exactly the same and fits perfectly !!)








I have many pictures from this engine workout and I will edit them into a small stopmotion movie, which i'll proudly share later ;)

Keep riding dirty !!! ;)

Nice greetings

[drsmk]

[jetdriverbr]

Can you tell me where or who makes your seal kit. I just got a winderosa kit and all but the crank seals are correct.