1990 Kawasaki KDX200 - Complete Budget Restoration/Rebuild
Cheyne Riggs Cheyne Riggs
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 Published On May 30, 2020

I bought this bike a few years ago for $750. It ran pretty good, but was very ugly, cobbled together poorly, and obviously not well cared for. I slowly repaired a few things here and there, and this past January I did a complete rebuild for Cam Niemela's #TEAMPRYME bike build contest. Here is a simple slideshow of the entire process from when I first bought it to now (in no particular order).

Since people love to piss and moan when I don't include every single part I replaced, here is a list of parts replaced, parts repaired, and parts added (to the best of my recollection):

Parts Replaced:
- Brake and Clutch levers
- Grips
- Handle bars (scored a NOS Fly racing bar for free)
- Headlight Switch
- Headlight and Taillight bulbs
- Front Fender
- Entire front fork and Triple clamp assy with new seals and fluid (during fork swap).
- Fork Guards
- Steering Stem bearings
- Front brake pads
- Gas tank breather hose
- Air Filter
- Spark Plug
- Radiators and Radiator Hoses
- Radiator shrouds and side panels
- Rear Fender (with good quality OE part)
- Complete BOLT body fastener kit
- Complete BOLT engine fastener kit
- Complete engine seal and gasket set
- Piston wrist pin bearing
- Silencer
- Exhaust gaskets and springs
- Swing arm sliders
- Swing arm bearings
- Linkage bearings
- Valve stem caps

Parts Repaired/Rebuilt:
- Carburetor rebuild with hoses
- Seat trimmed and custom seat cover made to fit
- Front Head Light and Number Plate assy
- Rear Shock serviced and rebuilt by RG3
- Brake hoses coated/re-finished with 16mm heat shrink tubing
- Engine and Body harness re-wired/repaired
- Damaged/frozen clutch cable freed and repaired
- Frame and Engine painted

Parts Added:
- Bar Pad
- Flag style Hand Guards
- Skid Plate
- Pipe Guard

I'm sure I'm forgetting a few things, if you've read this far and still have questions feel free to ask. I always tried to fix this bike as cheaply as possible, and I even set a $1,000 budget for the build contest (which I admittedly did go over by a little less than $200), so it didn't end up totally blinged out and completely brand new, but I am very proud of how it turned out and really wouldn't have it any other way. This bike was a blast to work on, and is even more of a blast to ride.

#Kawasaki #KDX200 #two #stroke #dirt #bike #desert #woods #enduro #trail #restoration #rebuild #project

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