Author Topic: What do you get in a kdx for $331.85 ?  (Read 6139 times)

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Offline kdx Geoff

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What do you get in a kdx for $331.85 ?
« on: October 29, 2015, 06:42:37 PM »

I've just picked up this 200 today.

Not sure if its a parts bike or something l may fix up some day. Its fairly complete ADR bike that was registered in NSW at some point in its past. I bought it off feebay and had Shaun deliver it to me from Sydney.



Its frame number 50 of the new model for '86 and has this paint dab and number on the headstem.



Recently, someone was having a go at trying getting it started as the carb has been fiddled with. When cranking it over it was clear the magnets had come adrift so off came the rusty flywheel. There's been some water in there over the years.



The good news is that 2 magnets had come adrift and naturally the bike stopped with no damage to the magnets or the stator. From there it looks like the bike was left alone, outdoors for many year going by the corrosion on the engine.

I'm hopeful after l repair flywheel we may have spark.

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Offline Nathan S

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Re: What do you get in a kdx for $331.85 ?
« Reply #1 on: October 29, 2015, 07:16:32 PM »
The number is from a long-past Four Day - probably 1987. Should be matching numbers on the hubs and engine cases.

I want that bash plate. You're not going to sell it to me, but I want it! :)
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Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #2 on: October 29, 2015, 09:49:35 PM »
The number is from a long-past Four Day - probably 1987. Should be matching numbers on the hubs and engine cases.





I want that bash plate. You're not going to sell it to me, but I want it! :)

The bashplate is in simular condition to the rest of the bike  ;D

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Offline GMC

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Re: What do you get in a kdx for $331.85 ?
« Reply #3 on: October 30, 2015, 08:42:27 AM »
Good find, you’ve never got too many KDX’s ;D

Araldite should fix the flywheel up okay after you clean it up

Strange that it is an ADR model.
The 86 models were usually silver framed with unpainted hubs and were non compliant US spec models.
(whereas the 87 A& 88’s were complianced green framed with black hubs)

It does however have the ADR headlight and what looks like indicator mounts on the rear of the frame which wasn’t normal for 86.

Frame No 50?
Is it a late build for 86?
Start of the 87 compliance models perhaps???
My 200 that I bought in early Feb in 86 is frame No 003635

Yes the paint markings will be typical 4 day markings, from memory on the frame headstem, both hubs, muffler and I think barrel or crankcase.

86 Four day No. 16 was Mathew Phillpott that rode in the Wollongong club team however he was in the 125 class.

87 Four day No. 16 was Mark Robbins who was on a Kawasaki in the 200 class. He was in the ACT Trophy team.
Finished 19th in class , 6 places behind Eldridge who also rode a Kawasaki that year.
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Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #4 on: October 30, 2015, 10:44:29 AM »

Thanks for the info Geoff  :)



It still has the wiring, horn, flasher can, ignition switch & key and switchgear on it.

I fixed a loose flywheel magnet on the 200 l ride with this quite a while ago with no issues so far.

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Offline Nathan S

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Re: What do you get in a kdx for $331.85 ?
« Reply #5 on: October 30, 2015, 01:36:47 PM »
87 is silver frame, black motor, with compliance.
88 is green frame, silver motor, with compliance.

Don't be mislead by the compliance dates. They're only very loosely related to when the individual bike was made.

The fact that it's a KDX200D also shows that it is a 1987 model.
The 86 models were Cs.
In the USA, they had C1 (86), C2 (87) and C3 (88).
In Australia, they were C1 (86), D1 (87) and D2 (88). GE always got it wrong and called the Aussie D models C2 & C3.



Gasket goo makes me nervous. I'm with Geoff M: araldite. I also flow the araldite around the magnets so they support each other.
« Last Edit: October 30, 2015, 01:41:11 PM by Nathan S »
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Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #6 on: October 30, 2015, 02:03:03 PM »
a bike with competition heritage Geoff? don't waste another minute fiddling with it, back on to fleabay with the words "Le Mans, Bathurst, Aust Grand Prix" etc and put 5 k on it. ill take 15 hunnert for the idea....

Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #7 on: October 31, 2015, 04:15:27 PM »


After cleaning and reattaching 3 magnets to the flywheel, l had spark  :) The '86 flywheel is a tad bigger than the '83-'85 flywheel. l didn't try swaping the earlier flywheel/ignition onto this 200 but if there had have been no spark, that'd been the next step.



l think the last persons attempt to start the bike was to put some fuel in and see how we go. There was no sign of this crap past the carb.



Started right up and idled. I poured a bit of oil into the plug hole and crank case yesterday and that's why we're smoking so much today.
Next step will be to service the power valve setup. I imagine it'll be locked up, and see if there's any gears as the lever is very loose and is just flopping about.

https://www.youtube.com/watch?v=Zyy9OKfKZIA
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Offline LWC82PE

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Re: What do you get in a kdx for $331.85 ?
« Reply #8 on: October 31, 2015, 04:42:52 PM »
Sikaflex would work really well with the magnets too. They would never fall off then.
Wanted - 1978 TS185 frame
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Offline chippy

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Re: What do you get in a kdx for $331.85 ?
« Reply #9 on: October 31, 2015, 05:18:16 PM »
Ticking over just nice Geoff. Good get.
                                          Cheers Chippy.

Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #10 on: October 31, 2015, 07:00:26 PM »
my bet is the PV gears will be sheared off and the valves gummed up. pretty common

Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #11 on: October 31, 2015, 09:10:31 PM »

my bet is the PV gears will be sheared off and the valves gummed up. pretty common

Nah, l don't want that  ;D
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Offline GMC

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Re: What do you get in a kdx for $331.85 ?
« Reply #12 on: October 31, 2015, 10:35:52 PM »
Not sure about the gasket goo to hold the flywheel, mostly because it sets soft.
Cases glued together with this stuff can always be pulled apart.

When I finally found a 175 flywheel years ago I set it up on the bench and flowed Araldite all around the magnets. Took a few days as I would glue up one section then after it dried I would rotate around to do the next bit.
Used Bluetack to form a 'dam wall' to stop it running everywhere.

My theory was that the Araldite would absorb some of the shock that is inevitable when fitting and removing the flywheel.



This model KDX has an odd size carby (as far as the inlet and outlet sizes are concerned) so you can't just bolt in a new Mikuni without having to make up adapter rings so it will fit the manifold and airbox boot.
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Offline GMC

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Re: What do you get in a kdx for $331.85 ?
« Reply #13 on: October 31, 2015, 10:41:36 PM »
87 is silver frame, black motor, with compliance.
88 is green frame, silver motor, with compliance.

Don't be mislead by the compliance dates. They're only very loosely related to when the individual bike was made.

The fact that it's a KDX200D also shows that it is a 1987 model.
The 86 models were Cs.
In the USA, they had C1 (86), C2 (87) and C3 (88).
In Australia, they were C1 (86), D1 (87) and D2 (88). GE always got it wrong and called the Aussie D models C2 & C3.



Gasket goo makes me nervous. I'm with Geoff M: araldite. I also flow the araldite around the magnets so they support each other.

Didn't know the 87's were silver frames!

The C1 to C3 were the US spec which is where GE may have been getting his info from.
The D models were the Aussie compliance models so the D's won't usually show up on international parts lists
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Offline GMC

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Re: What do you get in a kdx for $331.85 ?
« Reply #14 on: October 31, 2015, 10:46:07 PM »
Pity these models are considered modern bikes by many, when I get mine running we will have to escape to NSW for a Vinduro

Meanwhile here's some inspiration for you (or maybe a distraction!)


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Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #15 on: November 01, 2015, 06:54:29 PM »
id spend a week getting a pipe ready for that model :o 8)

Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #16 on: November 02, 2015, 05:47:30 PM »

Meanwhile here's some inspiration for you (or maybe a distraction!)




 8)

Inside of the cases are nice and clean and the oil that came out was reasonably clean too.
The PV setup was all free moving and appears undamaged, but the little lever that connects the governor to the shaft that moves the rack has broken off at some point in the past. It wasn't in the cases.


I'm not used to being able to buy new parts from the dealer but the advance lever is available new from Kawasaki for the grand sum of 13 dollars.



The bit on the left is what was left of the old one. Any ideas why this broke ?



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Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #17 on: November 02, 2015, 06:08:48 PM »
the valves and rack would be gummed up from low rev application's over time until it suddenly got revved to pv actuation revs but as the pv's are now  seized, something breaks. usually the alloy teeth on the individual pv's get sheared by the metal rack teeth. when the PO realises there is no top end on the bike, they strip it, clean it all up and then wonder why its still not working cos your little bracket broke instead of the teeth on the pv's...a good thing as I believe new pv's are hard to come by....tho I believe you have a cache of spares that even Kawasaki Australia is eyeing off....

Offline Nathan S

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Re: What do you get in a kdx for $331.85 ?
« Reply #18 on: November 02, 2015, 08:01:45 PM »
The C/D model PVs are far less problematic than the E/F models'.
No idea about part availability for the earlier bikes, but it is a PITA for the E/Fs.

I believe the arms break through fatigue when the PVs are jammed. The E/F models use the same shitty design for their actuator arms, which break too...
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Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #19 on: November 27, 2015, 05:19:59 PM »

All the parts to the PV setup work with the advance lever fitted. I'd like to find out what caused the lever to fail.



As the engines on the bench and now apart, I've honed the sleeved barrel out to 66.07mm (service limit 66.10mm) to get rid of the almost all of the scoring.
The piston has been sent off to get the skirts coated with a "Molybdenum Disulfide DF1 coating" of 1 thou to increase the diameter by 2 thou and take up some excesses clearance with the old piston. l could have bought a new piston, they're about on feebay but this was less than half the cost and cheap enough to try out.

I'll do the main bearings and seals too, the ones I'm replacing are originals.
The cranks are different between PV and non PV engines. The PV crank has the primary drive gear splined.

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Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #20 on: November 27, 2015, 07:43:26 PM »
going the whole hog with this one Geoff?

Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #21 on: November 27, 2015, 09:37:17 PM »
going the whole hog with this one Geoff?

I had a new set of rings on the shelf and its only a small step from there to crank bearings and seals   ;D

 
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Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #22 on: November 28, 2015, 08:00:15 AM »
yep, a "bored old fart in the shed" step from fitting rings..... 8) I know how it happens.

Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #23 on: December 01, 2015, 03:58:15 PM »

Got my coated piston back and happy with how it's come up. Its going back together with 5 thou clearance (Manual says 3 is standard clearance) and new rings. The crank's within serviceable limits too.



That'll be the engine sorted (enough) with crank bearings and seals ($40) piston ($53 inc postage) and rings ($25)
All up I'm in about $463  :)
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Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #24 on: December 01, 2015, 10:04:08 PM »
that's a rough lookin piston there godfrey...

Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #25 on: December 01, 2015, 10:56:39 PM »
that's a rough lookin piston there godfrey...

I've got others  ;D
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Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #26 on: December 02, 2015, 07:17:28 AM »
im sure... ::) its still a bargain bike....if I paid 200 for a bike the it would be welded together from the crank pin to the rear sprocket with rust >:(

Offline floberts

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Re: What do you get in a kdx for $331.85 ?
« Reply #27 on: July 15, 2016, 04:18:11 PM »
Sorry to hijack the thread, but what does the red paint / epoxy stuff on the outside of the magnets do?

I was putting my PE175 back together last weekend and it had come away from the magnets in some spots and was loose in general so I took it all off.... Should I have put something there to replace it?





Ben

Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #28 on: July 15, 2016, 06:22:20 PM »
I think its to assist in holding the magnets into the flywheel.

Offline fred99999au

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Re: What do you get in a kdx for $331.85 ?
« Reply #29 on: July 15, 2016, 10:37:38 PM »
I missed this thread also and would like to know what the coating is on the piston and from whence it came?

Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #30 on: July 16, 2016, 09:26:52 AM »
I missed this thread also and would like to know what the coating is on the piston and from whence it came?

"The piston has been sent off to get the skirts coated with a "Molybdenum Disulfide DF1 coating" of 1 thou to increase the diameter by 2 thou and take up some excesses clearance with the old piston. l could have bought a new piston, they're about on feebay but this was less than half the cost and cheap enough to try out."

http://www.hpcoatings.com.au/

Still haven't got the top end back on this yet  :(
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Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #31 on: August 05, 2017, 04:38:18 PM »

With the move to pre '88 for VERi and next year being the 10 year for Harrow l thought I'd sort this bike out and ride it next year as it has a bit of history.

I had a bit of an investigate today and spoke to the original owner....it was Mark Robbins and he did ride it in the '87 4 day.

Hoping to get some pictures of the bike at that event off him in '87.
Its not very pretty today though but still has the ID from that event.




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Offline GMC

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Re: What do you get in a kdx for $331.85 ?
« Reply #32 on: August 06, 2017, 09:07:46 PM »
The 200 class was big in 87
58 entrants
only 24 finishers
Seems the only bikes to ride were the KDX (39 entrants) or the IT (19 entrants)





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Offline kdx Geoff

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Re: What do you get in a kdx for $331.85 ?
« Reply #33 on: August 06, 2017, 09:40:13 PM »


87 Four day No. 16 was Mark Robbins who was on a Kawasaki in the 200 class. He was in the ACT Trophy team.
Finished 19th in class , 6 places behind Eldridge who also rode a Kawasaki that year.


Thanks for that entry name Geoff, that got me started.

Mark on his kdx200 at the 4 day in 1987.

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Offline 80-85 husky

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Re: What do you get in a kdx for $331.85 ?
« Reply #34 on: August 07, 2017, 12:54:51 PM »
nice pedigree there Geoffrey, cant beat those painted on numbers for a bit of bling...beats a chrome exhaust pipe every time

Offline tymes

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Re: What do you get in a kdx for $331.85 ?
« Reply #35 on: August 07, 2017, 09:49:59 PM »
Isnt it awsome to see a bit of history, the results form, the photo from the 4 day and the bike now. Thats gold. Well done for digging these things up.