motorcycle guys... What is wrong with my KDX? Update 2/6/10: Operation fix KDX!!

[KDXSR5]

So it has been over a year since the kdx has been ridden. I am getting really antsy, and want to ride again! So let me tell a story on why I have not ridden it.

About a year ago, my friends and I were having a friendly race around the ORV park. The course led us through creeks and mud holes and stuff. Well... I was going through the last mudhole, and I hit a berm that was under about two feet of water. I dumped the bike and killed it ASAP. I picked it back up out of the water, and pushed it out of the puddle back onto dry land. I then proceded to remove the spark plug, and turn the bike upside down to get the water out. I then righted the bike, and kicked it over a ton of times to try and get all of the water out. I then put in one of my spare plugs, and the ol' trusty kdx started first kick! I rode it back to the truck, loaded it, and drove home.

Now here is where the trouble begins. I took the kdx off of the trailer, and tried to kick it over... guess what? The kick starter didn't even move. I then tried to push start it... no luck there. So I got it up to the shed by pushing it in neutral, and I took the cylinder head off and the jug off to make sure the piston wasn't just rusted in place. No luck there, it still wouldn't kick over.

So I got frustrated and left it sitting in pieces for about a year. Now I need to get it running again, or my dad is going to force me to sell it. I am thinking crank bearing or transmission bearing. What do you think? Please help me!

[brainlessfool]

if it would not move after droping the clutch in gear, crank is a good beat. how long did you let it set after riding it back to the truck? hours? days? weeks?

[KDXSR5]

I rode it back to the truck, loaded and went home were I unloaded it and attepted to start it. Total time I would guess about 30-40 minutes.

[brainlessfool]

thats not enuf time for it to rust. unless we're talking some REALY close fitting stuff. I mean REALY close.
don't think your going to that off the show room floor.  junk (rocks) in the gears?

[KDXSR5]

I am not sure. I did not drain the transmission fluid, because I am stupid, so there may be something in there. Like I said, all I did was pull the jug because someone told me that the piston may have rusted into the cylinder. But I have figured out that is not the case. So what do you suggest? I pull the rest of the motor/transmission and crack it open to see what I can see? I just don't want to get into it way over my head and end up leaving it sitting for another year.

My dad's boss, an enduro racer who used to do the national circuits back in the day (in fact, if I rememeber correctly, he was national champ in his class back in 97), said he can help me fix it, but I would have to pay him a small amount for his time and the use of his tools above the price of the parts I will need to fix the bike. I want to do as much as I can without his help to minimize the cost of fixing the bike since I am in debt about $1500 right now.

[brainlessfool]

Well I think your eather going to have to up some $$ for the help. or sell it. sorry. 

ini over you head is no fun. and taking it farther apart will make it worth even less.

[KDXSR5]

Well, I am definitly not selling it. It is like my toyota; tough as nails and will last forever as long as you don't do something stupid. And guess what? I did something stupid. I guess it looks like I will be getting help then. Any other ideas? Anyone?

[kneedownnate]

I am thinking crank bearing. What do you think?

  though there is a chance that your starter gears are rusty too 

[KDXSR5]

I guess I am in for a large amount of work then. Thanks for the input guys! I will add this to my long list of stuff to do.

[Misfit4Runner]

try dirtrider.net ehy got a few KDX riders from all types of areas their

[Duffil]

so you dumped it in a pond a year ago and never drained the case? your bearings are , and probably the trans is rusted also.  time to split the case homie.

[kneedownnate]

try dirtrider.net ehy got a few KDX riders from all types of areas their

With their huge following, I'd be willing to bet there's a kdx board out there somewhere too!

[KDXSR5]

yes, I was a dumbass and did not drain the transmission. I may end up just buying a new (used) transmission and engine for it instead of trying to repair this one.

I have been on a couple kdx boards, and they have not been a ton of help, but I will try again sometime soon.

[Duffil]

yank the clutch cover and see how bad it looks.  You don't want to swap in an engine. FedEx it to me and I'll rebuild it for you.

[Hammerhead]

Duff is right - Pull the clutch cover to see what it looks like.  That will be a good indicator of the condition of the tranny.  Also, pull the magneto cover and take a look...

[kneedownnate]

I saw a kdx on the street today, but I've seen him before and seem to remember seeing the same bike for sale on craigslist a while back.

[KDXSR5]

Ok... took the dirtbike into the basement to tear apart and rebuild.

All bearings are toast except head bearings.

Rust.

Suspension is toast, it will be rebuilt with proper weight springs.

Rust.

Everything is very dirty. Cleaning is sucking.

Rust.

I need new tires before I race it again, if I ever do race again.

Rust.

Brakes are shot.

And did I mention there is a lot of rust? Yeah, I am working on that too.


I had to grind out the swingarm bearings with my dremel, and I have broken a few rusty bolts, but aside from that stuff, and some ghetto ass wiring I did back when I was 13 or so, everything is going ok with the teardown.

I am waiting on tax return to put a $600 order in for bearings and brakes and other associated parts. Pretty much ALL of the wear parts on the bike. I am also doing some upgrading with a nice FRP chain slider and a nice metal rear caliper guard because I broke the stocker.

As it sat after Day of Destruction:




Then down to the basement, followed by almost completely torn down. I am painting some stuff while I have it all apart too. I figure I might as well get a good chassis together and worry about the engine when it actually starts to get nice out.

[KDXSR5]

Ok, I ordered all of the bearings I need and some good bel-ray grease and a few other misc. pieces so I could get discounts. This is going to end up being very expensive!

I shall keep a somewhat accurate running total, as horrible as it looks

BEARINGS:
-Swing arm bearings: $50
-Front Wheel Bearings: $20
-Rear Wheel Bearings: $20
-Shock Bearings: $37
-Linkage Bearings: $72

BRAKES:
-Front Brake Pin: $4
-Rear Brake Pin: $8

CHEMICALS:
Grease x2: $12
Brake Fluid: $7
---------------------------
TOTAL: $230

[yotaneck13]

wow man...did ya figure out your motor issue.. my guess is with all the more time it sat after you started it back up there wasnt enough time to rust as was stated eariler but the water def caused something i have seen this one before when i worked for hetrick racing on a kx 125 it was dumped in the water i believe on a berm also and was drained right there even oil an tranny refilled an fired back up rode home parked for less than an hour an wouldnt turn over again when they tried piston was fine on tear down but the engine being hot an dumped into water colled it rapidly causing the crank and kick starter gear to cease when the engine warmed back up id check there first if not i can get it rebuilt pretty cheap for jus the parts an shipping no charge for labor hope it turns out something stupid tho

[KDXSR5]

wow man...did ya figure out your motor issue.. my guess is with all the more time it sat after you started it back up there wasnt enough time to rust as was stated eariler but the water def caused something i have seen this one before when i worked for hetrick racing on a kx 125 it was dumped in the water i believe on a berm also and was drained right there even oil an tranny refilled an fired back up rode home parked for less than an hour an wouldnt turn over again when they tried piston was fine on tear down but the engine being hot an dumped into water colled it rapidly causing the crank and kick starter gear to cease when the engine warmed back up id check there first if not i can get it rebuilt pretty cheap for jus the parts an shipping no charge for labor hope it turns out something stupid tho

I have not even torn into the engine/transmission yet really. I am going to fully rebuild the chassis and get the bike back together 100% minus engine/transmission, then work on engine/transmission. I need to save more money before I can do engine stuff. Once I get both engine/transmission back together, I will partially disassemble to get it out of the basement, then reassemble in the garage and hope for the best. This will be very slow. The first post was in May '08, and the bike had been seized for over a year before that. Obviously, it has been a while and this project has not been top priority. I decided it was time to fix it or junk it. I could not get rid of this bike, so I am fixing it.

[kneedownnate]

Glad you're finally getting back to working on it!  Sounds like it'll be quite a bit of work to get it up to par but will be worth it.  What year is it again? 

[KDXSR5]

Glad you're finally getting back to working on it!  Sounds like it'll be quite a bit of work to get it up to par but will be worth it.  What year is it again? 

2001

[kneedownnate]

Got it!  Just kinda surprised to see conventional forks on that late a model.  I've done two similar complete tear downs but with the intention of repainting the frames only.  It's fun and something I like doing, especially cause it can make such a difference in the way the bike looks.

[yotaneck13]

ok man def let me kno if ya need anything i can walk you through the rebuild or do it for you if u ship it to me

[KDXSR5]

Got it!  Just kinda surprised to see conventional forks on that late a model.  I've done two similar complete tear downs but with the intention of repainting the frames only.  It's fun and something I like doing, especially cause it can make such a difference in the way the bike looks.

I was going to paint the frame blue, but it is really not worth it because it will just get worn off after while and the green will show through and look horrible. Or I could strip the whole thing and then paint it blue... never mind, just the thought makes me sick! WAY too much work for a dirtbike.

I thought about just touching up the frame, but I am having a hell of a time finding any old Kawasaki green paint. Kawasaki changed colors a few years after this bike was originally built.

So, I am leaving the "patina" on the frame, and painting the swingarm, kick stand, and probably the bottoms of the forks along with a few other small parts. I am just painting them a cast aluminum color, much like stock. After a year or so, it will all look trashed again anyways.

I did paint that stupid purple fender bag BLUE!!! I tore mine apart in a wreck, and that one was free, so on it went.

I found a new rear fender in the garage, so that will be going on. I guess that's it for now.


PS: the KDX wasn't really improved upon much after I believe '95 or '96 (don't remember anymore) up until production stopped on them. So, they are using the "old style" forks. I have seen people install KX125 forks (which are inverted) on these bikes before, and if I really beat this bike hard while racing I would probably go that route. For now, these forks will work once I rebuild them.

ok man def let me kno if ya need anything i can walk you through the rebuild or do it for you if u ship it to me

Thanks for the support and offer for help man! I really appreciate it! I am having fun doing all this stuff, and once I get it done, it should be a blast.

[KDXSR5]

Oh, I accidentally broke one of the electric mystery box deals that hook into the ignition. I broke the mounting tab off. Hopefully someone on ebay or the like will be parting a KDX out so I can pick one up. If not, I guess I will figure something else out.

[kneedownnate]

Did it expose any of the electronics or just break off?  If you can clean it real well you could probably just attach it with an epoxy.

[KDXSR5]

Did it expose any of the electronics or just break off?  If you can clean it real well you could probably just attach it with an epoxy.

Nope no electronics exposed. I was going to try that first, I just don't now how well it will hold up over time. I guess I will find out!

[KDXSR5]

More Parts: NEW

SEALS:
Shock Seals: $30

SPRINGS:
Fork Springs .38 kg: $100

BEARINGS:
-Swing arm bearings: $50
-Front Wheel Bearings: $20
-Rear Wheel Bearings: $20
-Shock Bearings: $37
-Linkage Bearings: $72

BRAKES:
-Front Brake Pin: $4
-Rear Brake Pin: $8

CHEMICALS:
GOOD shock/fork oil x3: $30
CHEAP fork oil x2: $9
Grease x2: $12
Brake Fluid: $7
---------------------------
sub-TOTAL: $468

Total Shipping: $15

TOTAL: $483


The place where I have been getting everything, www.rockymountainatvmc.com does not carry springs, so I had to go with a different company and pay shipping on them. RMATVMC has great deals though with promo codes and free shipping if spending over $100.

[kneedownnate]

Yikes man, for some reason suspension linkage related bearings are always so expensive