Kmx200 - Now with full size pics!

steady eddie · Nova Slayer Joined: 03 Sep 2006 Karma :

So this week I finally got round to sorting my kmx out. Dunno why I waited til the hottest week of the year Rolling Eyes

i blame work.

I bought this unseen on evilbay, a bit pissed one night, put a cheeky bid in (£670) and fookin won it! When Mrs Eddie found out she nearly left me Laughing

But being a man of my word i hired a van and drove 340 miles to Nuneaton (I didn't even know where the fuck that was) through the night to pick it up.

It had 10 months mot & tax and only 4 owners from new. But each owner probably let his 5 mates have a go Rolling Eyes

It was a bit ropey but was all there. Well, except the fuel tank lock. And the engine number Rolling Eyes

. Funny how the description forgot to mention that...

Did 500 or so miles on it no bother then it seized up https://www.bikechatforums.com/viewtopic.php?t=265743&highlight=

So let the rebuild begin
https://s6.postimg.org/o5yum4lf5/kmx_rsz.jpg

Started undressing her
https://s6.postimg.org/uoroz1xm9/rsz_2013_02_17_175035.jpg

Everywhere I looked, bolts were missing or had been replaced with imperial stuff Evil or Very Mad

https://s6.postimg.org/ugr702gdt/2013_02_20_23_50_45.jpg
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Fz50>Ts185>Rd125Lc>Cb250n Superdream "Deluxe" (!)>Kmx200>Tdr250>Yzf600 Thundercat>
Current bikes: 1997 Fireblade RRV & 1989 KMX200

SQL · World Chat Champion Joined: 08 Aug 2012 Karma :

£670!! Is the frame made of titanium??

steady eddie · Nova Slayer Joined: 03 Sep 2006 Karma :

With the engine on the bench I started stripping it
https://s6.postimg.org/az5qbly7l/2013_03_01_23_37_02.jpg
https://s6.postimg.org/d54mjur1t/2013_03_01_23_48_41.jpg
https://s6.postimg.org/pl1cdlkdt/2013_03_01_23_49_03.jpg

I've split the cases and now I just need to get the crank out so I can get it rebuilt. Got hold of a genuine conrod kit for £50 (rrp £120!). Not sure whether to use a Matika piston kit (£50 with rings) or a genuine one (£65, plus £40 for rings) which seems a bit steep really Sad

With the engine out, I could see how bad the frame was. I was going to spray it with rattle cans but it will probably look shit, so I had the bright idea of getting it powdercoated Cool

https://s6.postimg.org/5djb7jxip/2013_02_24_21_48_47.jpg
https://s6.postimg.org/ol6g45fu9/2013_02_24_21_49_00.jpg
So started stripping it down which went well enough, no seized or snapped bolts

Swingarm off
https://s6.postimg.org/o3fw21fn5/20130709_000859.jpg
https://s6.postimg.org/cptcqu54h/20130709_000910.jpg
https://s6.postimg.org/ab62k5e9d/20130709_000922.jpg

A lot of the loom has been modified Rolling Eyes

https://s6.postimg.org/keusgav01/20130713_230320.jpg
https://s6.postimg.org/fp4urp3zl/20130713_230324.jpg
so that all needs sorting, as does the shock (are they rebuildable?)

Then the front end
https://s6.postimg.org/tdpg72p9t/20130719_231804.jpg
https://s6.postimg.org/u0ocwlm5t/20130719_235505.jpg
https://s6.postimg.org/c33mssn01/20130719_235515.jpg

And this is where I'm upto now
https://s6.postimg.org/nyqdgytf5/20130720_002801.jpg
https://s6.postimg.org/jn1rrymi9/20130720_002742.jpg

Need to get the frame powdercoated, the crank rebuilt and clean / paint all the dirty bits I have strewn all over the garage then I can start putting it all back together Very Happy

and here's the pictures from the ebay ad when I bought it
https://s6.postimg.org/mv177w2gh/SC20121007_164244.png
https://s6.postimg.org/tpbhxkv3l/SC20121101_215002.png
https://s6.postimg.org/4us03ia9d/SC20121101_214950.png
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Fz50>Ts185>Rd125Lc>Cb250n Superdream "Deluxe" (!)>Kmx200>Tdr250>Yzf600 Thundercat>
Current bikes: 1997 Fireblade RRV & 1989 KMX200

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Fast progress there mate!

I'm ashamed to say that my identical 88 version has been sat at the same stage as your photo ''with the swingarm off'' for over a year, and was previously sat without the engine or plastics for about 4years before that! Shocked

Looks like a bodger has been at your bike too, with all that sealant blocking the waterways. Mine was similar and it was obvious that the head gasket had been re-used after slapping bathroom sealant all over it.

At least the ports in your cylinder don't look to have been messed around with, and the cylinder damage is minimal on yours, maybe just a bit of smeared aluminium over the bore. Mine has big chunks missing and has been hacked around with.

good luck with your project and don't forget to tell us how much it costs for reference.

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Not sure whether to use a Matika piston kit (£50 with rings) or a genuine one (£65, plus £40 for rings) which seems a bit steep really

Go with the Makita piston set, wont notice any difference, and being half the price, you can change it more often (which will maintain the performance of the engine)

so that all needs sorting, as does the shock (are they rebuildable?)

Yes, they can be rebuilt. Rebuild costs start at £100 for strip down, new seals and oil and re-gas. Can run to more than that if the internals are heavily worn. If the chrome has gone on the shaft, and it cant be polished out, then £30-35 extra etc.

Also, i've made the mistake of getting a crank rebuilt without replacing the main bearings, as they seemed fine. Few thousand miles later they went too, so worth doing at the same time, if you weren't already intending to do that.

That gasket in the coolant passages is pretty shocking, you're going down the right route rebuilding the whole bike if the previous owner was capable of doing that !

Look forward to seeing it come together !
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1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

bladerunner · World Chat Champion Joined: 09 Sep 2006 Karma :

Kmx 200's are great fun little bikes. I paid the same for a kdx200 earlier on this year but got it delivered from a similar distance for £140 and knowing the bike hadn't been run in 3 years expected a total rebuild before I could use it....but apart from shot water pump seal and sheared kips valves I found in the exhaust !!! It's put up with a lot of abuse this year already but deffo going to do the same as you over the winter. If the plating on the bore is ok I use brick acid cleaner applied with a cotton but to remove the traces of Ali after a bit of gentle wet and dry to remove the worst. It dissolves the Ali but leaves the nikosil plating so don't pour it down the ports!
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Current bikes...cbr929, KDX200's, Rd125lc mk2, RGV250's

steady eddie · Nova Slayer Joined: 03 Sep 2006 Karma :

Thanks for the good advice Wink

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

bladerunner · World Chat Champion Joined: 09 Sep 2006 Karma :

Bladerunner - I was looking at kdx's before I got this, nicer looking bikes I think, bit more crosser ish Cool

[/quote]

Aye the kdx is a bit more offroad based ie no battery, pre mix different suspension...oh and about 30 mph less top end lol!
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Current bikes...cbr929, KDX200's, Rd125lc mk2, RGV250's

Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

This should be interesting, I like KMX's. I have nothing useful to contribute really. Just letting you know to keep up with the pictures. Very Happy

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Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.

steady eddie · Nova Slayer Joined: 03 Sep 2006 Karma :

So Mrs Eddie was in work today, which meant I could do this

https://s6.postimg.org/6ew03bgc1/20130726_123516.jpg

10 mins @ 260 degrees worked a treat, bit of a tap and I got the crank and 1 bearing out, but can I shite get this 1 off

https://s6.postimg.org/4loi195rl/20130726_132621.jpg

Then I noticed a hairline crack in 1 case Shocked

https://s6.postimg.org/so5bw4mep/20130726_132715.jpg

Didn't notice any leaks from here before so let's just pretend I didn't see it Neutral

Arse. Anyone (except Paddy Wink

) fixed a crack like this before? JB weld / Tig weld / bit of 3 bond?
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Fz50>Ts185>Rd125Lc>Cb250n Superdream "Deluxe" (!)>Kmx200>Tdr250>Yzf600 Thundercat>
Current bikes: 1997 Fireblade RRV & 1989 KMX200

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

steady eddie · Nova Slayer Joined: 03 Sep 2006 Karma :

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

steady eddie · Nova Slayer Joined: 03 Sep 2006 Karma :

Got the barrel and crank posted off today to Road and dirt performance in bradford for a replate and new conrod kit to be fitted. They're also gonna fit an insert into 1 of the head bolts that's stripped.

bought a genuine head gasket off eBay for £11 but it turned out to be for a 125, messaged the seller (Pidcocks) AFTER I'd left (good) feedback and they refunded me in full immediately and told me to keep the gasket, SO A BIG MENTION FOR PIDCOCKS CUSTOMER SERVICE Thumbs Up

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Fz50>Ts185>Rd125Lc>Cb250n Superdream "Deluxe" (!)>Kmx200>Tdr250>Yzf600 Thundercat>
Current bikes: 1997 Fireblade RRV & 1989 KMX200

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

waynenoonan12... · L Plate Warrior Joined: 01 Apr 2011 Karma :

quite like these bikes. i had a suzuki ts200r not so long ago and they seem to be very simlar. ended up seizing mine as well but parts for them seem none exsistant. keep up the good work.