Kawasaki KDX200 Info

[Wobbly]

Ok, I've managed to pick myself up a new trail weapon, a mighty KDX200 :D However, what on first appearances was a well used but good example is quickly turning into a bit of a dog :lol: Actually, that's a bit of an overstatement, but it is going to need a bit more work than what I originall foresaw.

So, before I start banging my head against a wall, is there anyone out there with some good KDX info? Someone with a service manual for sale or borrow would be fantastic :up:

My first challenge is that the farmer who originally owned it decided that he couldn't waste the extra 10 minutes it would have taken to unplug things and, instead just cut the main wiring loom off before any of the plugs for headlight, switchblocks, etc :roll: So I need to work out how to wire it up so that the headlight is just permanently on (for rec reg inspection) and how to get the tail light working and why it isn't given that I just re-wired this after he cut that off as well :roll: :roll:

WHAT IS IT WITH SOME PEOPLE??? Sheesh, talk about pain in the arse...

[Flash]

check with vic roads you may not need to take it there, you may only need to tell them it has lights etc. I have been told that it is a bit like trailer rego in that way.

[LilydaleIsMulletCountry]

post a photo, i had kdx200 stolen at the start of the year
and what year model is it

[Flash]

Busted!! :lol:

[Wobbly]

lol ... its a 97 ... and yes I already quoted the VIN and Eng#'s to VicRoads to do a check on it :D

[LilydaleIsMulletCountry]

ok, its all good, use the kdx too look for mine then.
mine had a blue seat and blue forks :)

[Wobbly]

Blue forks would be the upside down ones from the 93-94 model wouldnt they? Nah, afraid mine are just the stock right side up boring silver forks and black seat. And factory non-matching front and rear rims (rear gold, front silver) :lol:

[dicky]

hmm... different rims, butchered electrics...
how much did he pay you to take this?

dicky.

[Wobbly]

Come on dicky, it all looked good under the light of a small hand held torch!! :lol:

[Sibbo]

The important stuff, how big are the wheelies it pulls? Better than the DR-Z?

[Wobbly]

Hardly! :lol:

[Wobbly]

Ok, so the thing has been running like crap so time to tinker :D

http://vsmr.net/albums/nmilne_non-motard/KDX_Undressed.jpg

[Muzzard]

Is it just the picture or has it got one seriously bent up left radiator?
And is the rear rim an Excell?
Apart from that certainly looks the goods...

[Wobbly]

I'll have you know that the left radiator has been stylistically altered to best mesh with the required feng shui needed when the bike is positioned in a northerly aspect.

Err, ok, yes, it's pretty bent then :P

Now I just need to wallop the front so I can replace it with an excel as well :lol:

[Wobbly]

Ok, I've now managed to lose all spark :x

Long story short, pulled and stripped the carb again, bike wouldn't start, pulled the plug out and no spark. Replaced the coil, no spark. Played with the wiring, no change. Measuring the voltage going from the CDI to the coil seems to register nothing, but it would be strange for the CDI to pack up right now? Pulled the magneto cover off and checked that the pulse generator looked ok and didn't have too much air gap (has almost none).

:cry:

Anyone know a good bike electrician in melbourne? :?

[Muzzard]

Neil, Ring Rick Wason 0357212752 and ask for Garth or Rick as it is a workshop question...
Both are very knowledgable and will help you out if you mention where and who you are, (Rick will remember you)...
I know they utilise the services of a specialist motorcycle electrician, not sure of location, but turn arounds are very very quick...
Give it a whirl. :)

[Wobbly]

Will keep that in mind ... when i was at eastern m/c wreckers in ringwood they mentioned they had a full ignition testing rig that could to high point in time voltage measurement and all sorts of crap so I dropped it off this arvy after getting the *cough* comprehensive rec reg inspection done and a plate for it :)

[Flash]

How the Fu&* did it pass if it doesn't run???
Didn't you have to take it there?

[Wobbly]

Guy walked out, looked at bike on trailer, scratched his head until he found the numbers, noted that it had a headlight and tail light, then buggered off back inside to his comfy seat and filled out the paperwork.

:D

[dicky]

So Sibbo should have no problems getting the KX500 donk into a different frame then.

dicky.

[Flash]

Mmmm 700cc 2 stroke rotax in a wr frame :-k

[Wobbly]

Well, at least it looks a bit better now ... be even better if it actually moved under its own power :D

http://vsmr.net/albums/nmilne_non-motard/DSC01323.sized.jpg

http://vsmr.net/albums/nmilne_non-motard/DSC01324.sized.jpg

[Flash]

What the fuck did you get the horn and hand gaurds off??

[Wobbly]

The horn cost me $5 from bikemart and will, of course, be junked. This photo was taken just before I loaded the bike on the trailer for the rec reg inspection - forgot to put the mirrors on, but apparently that doesn't even matter as much as having a bike that actually goes :lol2:

The handguards are the original kdx ones which I'll probably throw out in favour of some barkbusters at some stage. And no ash, I don't intend on going over the handlebars very often :lol:

The headlight is a standard polysport one (quite a good unit actually, has good straps for multiple different fork diameters and stuff). The front guard is from the current model KX...

[Wobbly]

By the way, do you like the rear guard being held on by cable ties ;)

[Flash]

And no ash, I don't intend on going over the handlebars very often :lol:


:roll: :roll:
You have forgotten I've seen you ride on the dirt!! :lol:

[Wobbly]

No you haven't - when was I ever in front? :lol: :lol: :lol:

[Wobbly]

Been meaning to pull the handlebars off the kdx since I noticed that they were kind of twisted (along with being meaning to replace the leaking fork seal and do the top end :roll: ). Finally did that today ... the bars themselves were straight but were twisted in the mounts.

I pulled those out and the rubber bushes were pretty junked so I'll need some new ones of them ... i've heard the kawasaki ones are fairly crap, but who makes aftermarket ones that would suit?

I also had a look at the yokes and I'm trying to work out whether the left hand side mounting hole has been elongated as well?

http://vsmr.net/files/kdx_triples.jpg

[Muzzard]

If the risers are bent Neil you can straighten the post in the vice.
Rubbers,
Good luck, I made a pair outta a Nolathane suspension bush for my XT500G. They were shit loads more secure than the originals and didnt flog in the time I own the bike as a VMX racer.

[dicky]

the lhs hole does look out of round, but it's pretty hard to tell from a photo.
judging by what i've seen of your tool kit, i reckon you've got a filthy big reamer sitting around somewhere.
drop the tip of that in the hole, you can see if it touches all the way round or not, spin it backwards and see if it marks the inside face all the way round.

dicky.

[Flash]

Hey Neil
It seems we should be doing a big bore kit in that thing!!

Did you ever get onto the V force reeds?

[Wobbly]

Not yet mate, but it's on the list ... figured I'd just ride it stock to begin with and then make small changes along the way so I can work out what works best etc. First thing is a new top end, then will stick in the diff jetting, then change pipe, then reeds, then big bore, then shaved head, then ignition timing, then BANG! :lol2: