KDX Project - 2005 Kawasaki KDX 200 Complete Rebuild Woods Weapon - Bike Build - Project 2 Stroke
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- Опубликовано: 9 фев 2025
- We take a stock 2005 Kawasaki KDX 200 and turn it into an epic woods weapon from bottom to top. Enjoy!!
@lovefirstworld
Parts List:
@lectronfuelsystems - Lectron Carb installed after initial try with original carb. www.lectronfuelsystems.com
@millenniumtechnologies - Top end pristinely done by Millennium Technologies
www.millennium-tech.net
@factoryconnection - Suspension update done by Factory Connection, rides like a Cadillac.
www.factoryconnection.com
www.rtrwheellacing.com - Wheels anodized by Bob at RTR Wheel Lacing. He also put the KX250F front hub on the wheels for proper fit with the new forks.
@cycra - Hand guards
www.cycra.com
@fmfracing1973 - Pipe and exhaust are FMF.
www.fmfracing.com
@motocal.mx - Graphics by Motocal, I designed them on their site.
www.motocal.com
@galferusa - Brake rotors by Galfer
www.galferusa.com
@coremotousa - Brake lines are CORE Moto
www.coremoto.com
@imsproducts - Pegs are IMS
www.imsproducts.com
www.clarkemfg.com - Oversize gas tank from Clarke.
maier-mfg.com - Rear Fender.
@renthal_moto - some rental parts
@motosportinc - many of the parts came from Motosport.com
@kawasakiusa
Thanks to @hansenracingteam
#kdx200 #bikebuild #2stroke #kawasaki
I Love You!!
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This exact bike actually popped up for sale near me and it looks like the new owner hasn’t put too much time on it. He’s asking a good bit for it but it’s very clean!
You had me with the KLOTZ sticker! Go like the wind.💨
Sweet bike! I have 3 KDX220s. You might say I love them!
Ha!! Oh yea that's an addiction... Thanks for watching!!
I just bought an 87’ 200 any pointers?
My stock 91 KDX200 was the best thing I ever rode on two wheels!
Agreed!! Thanks for watching!
Just bought a 220 KDX. I may just have to tear into now after seeing this lol
Good luck!! It wasn't cheap but it sure was fun!! Thanks for watching!!
That's one mighty fine KDX 200. Awesome work!!
Thanks for that Phillip!! Appreciate you watching and commenting!!
Awesome build. The kdx is a legend. I just wish they were still producing them. 👍👍
Agreed!! Thanks for watching!!
I have a 95 sitting in the shop, received it for my 11th birthday in 2000.
I was rough on it . Hasn’t ran in years . This is the bike I have had in my dreams since I first joined the KDX forums years ago.
I was recently hit by a distracted driver on my Harley , it’s totaled , and my wife is asking me to stay off the road bikes . Now may be a great time to pull her out and follow my dream .
Excellent idea!! It's a great bike to build and so fun to ride!! Good luck and thanks for watching!!
How did you make out did you build it?
Love this video! Bought my 05 220 brandy new off the showroom floor and immediately started transforming it similar to what you did, except there were no 05 forks available yet of course, but found a pair of 03's from a KX250. Rode it every weekend for two summers then it sat for almost ten years until my son got bigger. He's 14 now and rides it and I'm so glad I kept it for him. He loves this bike. They are legendary in the woods and so easy to maintain. Here in the northeast we have a lot of steep rocky trails and the 220 lugs up those trails like it's on autopilot (steering stablizer is a must out here) Thanks for sharing this! made my day.
That's AWESOME!!!!! Great story!!!! Thanks for sharing that... Appreciate your comments!!
The Lectron legacy era carbs don't fit well even after Lectron machines the right side significantly, but the biggest issue here is the VForce3 reed cage pushes the carb back further than stock, which causes the inner top cover screw side interference. The $$$ Lectron Billetron Pro Series carbs + Lectron Long Body Adapter fit SIGNIFICANTLY BETTER, and also run even better and are more adjustable than the old school and HV Series Lectrons. The stock carb probably just needed a replacement OEM Keihin PWK33+ Long Body jet block gasket replaced, and jetted more properly. a #7 slide really cleans up the bottom end as well. A PWK35 Air Striker carb is the #1 preference though over the stockers, but if money is not a concern, spending double on the Lectron Billetron Pro Series is AWESOME! Better fuel range and fuel economy + cleaner burning due to the finer atomization of the fuel droplets of a metering rod carb like a Lectron or SmartCarb...
Nice Fredette FRP shorty kicker lever on there, I didn't see that mentioned! The initial video sounded like a bad connecting rod bearing rattling, although maybe that was the piston wrist pin bearing not the crank pin end rod bearing, or perhaps the notorious KIPS rattle of the old school powervalve design's main downfall, wear.
I wouldn't have any stock rims (from any manufacturer) and hubs stripped and anodized with new spokes when you can get significantly stronger and usually lighter brand new anodized/coated rims from Excel and D.I.D., and can get a '90-'02 Talon rear hub + KX250F etc front hub to match your fork upgrade swap, laced in 3-cross spoke pattern instead of the standard 2-cross, and Talon rims anodized in your color of choice out of their many color offerings (PURPLE!, green, gold, black, clear, etc...). Even "Excel Takasago" OEM rims off Yamaha YZ's and KTM's are an inferior grade over the aftermarket Excel Takasago and D.I.D. Dirt Star rims, not to mention the Excel a60 and DID Dirt Star STX which are stronger and lighter, or the Talon rims which are said to be the absolute best for the money.
Quite possibly the nicest kdx build on here!! Great video keep up the good work I'm inspired to get mine done after watching this!
Thanks for the kind comment Nathan!! Sincerely appreciate it!! Thanks for watching!!
As a kdx owner and cult member, INSPIRING. Stealing this build😎
Subscribed✌️
Thanks for that my friend!!
Funny Kid you got there in the background anywho super nice KDX man. Preserve it.
Picked up my second KDX a few days ago. Such great bikes. Great video.
Awesome!! Thanks for watching!
Hot tip.. Tilt the bike towards you before you start with choke on, helps with the fuel to the carb downwards pressure, guarantee start first or second kick.
Been doing that since my minibike days. Still works like a charm to prime it.
Hi, is that tip specifically for the Lectron carb or any carb in general. And does it make a difference which side of the bike you're standing on?
You forgot the mix gas?
If your holding the handlebars and your standing on the left of the bike tilt it downwards
That’s one nasty awesome KDX!
Thanks for watching Bill!!
I had this same exact bike. Mine just had a gnarly on it and some suspension work. Great bikes!
Good stuff!! Thanks for watching!!
Nice build. I just started a 2002 KDX 200. Gonna have Freddette do alot of the motor and suspension.
That should be excellent!! Good luck!! Thx for watching!!😎👍🏻
That's one very slick bike 👍
Awesome!! Thanks so much that Steve!!
Awesome video!...so wholesome working with the kids...much love & respect from Zimbabwe 🇿🇼🇿🇼🇿🇼
Thanks so much for that!! Great to hear from you!! Thanks for watching from Zimbabwe!!!!! Much love!!
That is a piece of art, I love KDX200's. Well played indeed!
I really want one ... they are so expensive out here tho, but I am realllyyyy wanting one to build like yours. Beautiful bike !
Appreciate the comments!! Thanks for watching and good luck finding the right one for a good price!!
I’m watching this because I just had one given to me! I’m excited! My last dirtbike I’ve had was a KX100
Had my Kdx 220 for almost a year, half of that its been not running do to maintenance/it having sat for 15 years, its mostly stock but a ripper. Awesome video!! Stoked to get to building mine, will definitely be taking some inspiration from you good sir.
Im boutta try snagging one of these up as a first dirtbike.
Perfect bike for a first! You'll love it!! Thanks for watching!!
Dang good documenting and a fantastic build!!! Well done !!
Sincerely appreciate that!! It was such a fun build!! Thanks for watching!!
You got me missing my KDX220 I built up almost just like that
Good stuff!! Thanks for watching!!
where did you find the last wing
Great job boys! 😎👍
Thanks for watching!!
Wow! I want to do that to mine!! Excellent
It was fun!! Thanks for watching!!
Awesome! You now have a dirt bike for life. Can you give us a cost breakdown?
Before we peruse a similar project! Defiantly down for that Lectron carb
just picked up the exact same bike yesterday. completely stock and original besides full fmf
Awesome!! They're so much fun!! Thanks for watching!!
Sweet build. Forever a fan of the KDX.
Appreciate that and agree!! Thanks for watching!!
Just bought a 2002 200 Australian model with only 1545 km on it and completely original. Hasn't been ridden in years and kept in a garage. Road registered , have ordered all the parts to turn it into a great trail bike. It will be a nice change from my beta 4 strokes i currently ride .Haven't ridden a 2 stroke since i sd my kdx250 in 2008.
That thing looks INCREDIBLE!!!!!
now I have to get one!!!!
I’ve got a 2002 KDX200 and I’m thinking I may have to make a west coast clone of your bike. Such a beautiful machine, well done.
Thanks for that my friend!! Good luck with your build!!
Great to see / watch your restoration and finding a way to make things work. Have heard very positive things about Lectron carbs and may install one on my KTM 640 Adventure. You have some fun trails to ride there ! And your youngest son is a ham!
Thanks for watching!!! It was a fun build. The Lectrons are great. I'm also using a SMARTcarb on my YZ125X and it's quite amazing as well.
Very nice job on your build. I bought a kdx200 for a winter build myself. Enjoy that bike.
Thanks for that!! Good luck on your build!!
Bike looks sick. Mods are great to!
I am so jealous! I have a 2003 220 and I’m probably going to model my build after yours. Nice work!
Awesome!! Thanks for that and good luck on the build!! They're so much fun to ride!! Thanks for watching!!
Definitely inspired was thinking of selling my 1995 KDX but I'm going to follow in your foot steps beautiful build
Good luck! It was challenging and fun!! Thanks for watching!!
Nice work fellas!! Enjoyed watching the build
Thanks for watching my friend!!
That is awesome I had one back in the 90s
They're so fun!! Thanks for watching John!!
Fantastic Machine
Thanks for watching!!! Appreciate the comment!!
Dang awesome build
Appreciate that!! Thanks for watching!!
Worlds best trail bike
Agreed!! Thanks for watching!!
She is beautiful! I have a 06. I love my bike. I wish I had that KTM money to put into it. Who am I kidding I'm happy with the 2000 I have in it.
Fun bike!! Thanks for watching!!
This is utterly awesome. great job on the refresh.
Thanks for that Kevin!!
Oh man if I was still medically able to ride dirt bikes and still had my 1999 KDX 200 I would send it to you and have you do the same exact thing to it.👍🏁
Awesome!! Glad you enjoyed it!! It was so much fun putting that bike together!! Thanks for watching!!
Nice video. I also have a KDX- had Jeff Fredette bore out my carb. Awesome difference. I did some work to engine as well. Runs great.
Great content! Cut and video in general well done! Wonder why I stumbled so late over this one, having your channel subscribed since quite a while.
Thanks for that!! Much appreciated!!❤️👍🏻
This is great, my dad bought me a KDX in high school. It's mostly sat since I moved away, now I'm back home and started tearing it apart. Great and fun video, seems like a really great family activity to share. You've influenced me on tricking it out a bit! Excited to get it going once the snow melts here. Now my dad wants to buy a KLX300! Haha
Nice!! Good luck!! Thanks for the comment and thanks for watching!!
It's great that you didn't cheap it out and as a result you got a lot more out of the KDX dna. Look at the time and money guys spend restoring old bikes that were never class-leading machines in their day. The KDX200/220s are worthy! They respond so well to the classic 2T mods. In one day you can transform the trail bike into a controllable ripper. Now you have me building some sweet wheels for my FRP ported 220. If you ride steep single track and like to hit the dunes or desert, I recommend having both FMF pipes for the 200 and ported 220s. I hope all the current KDX owners know what happened with other great low-cost 2T bikes like the Yamaha RDs - you can't afford one anymore. If Kawi ever brought the KDX 2T back, you'd prob get oil and fuel injection but pay $9K+.
It was a really fun build and it's holding up quite well!! It would be cool to see them come out with a new one though!!!! Thanks for watching!!
Very very good Job congratulations
Thanks for watching!!!
That is one sweet bike!!
Thanks for that!!!
Turned out good. I know I love all my KDX’s. I raced enduros in the A200 class (BJEC) it’s a 5 state event. 1st overall in class.
Excellent!! Sounds like fun!! Doesn't get much better than the KDX!! Great job by the way!! Thanks for watching!!
Hands down the best KDX build I have even seen! I have a 1995 Kdx 200. I have had it for 6 years now and will probably never let it go. It’s an absolute woods weapon! I have climbed some very extreme hills with this bike and have killed it on very tight woods single track. It has such linear power, but when you need that low end power/torque it will climb a mountain!! Thank you for listing the build parts. I was curious if you could tell me on how much you think you put into this build (minus the bike cost). I really appreciate the feedback. Ride safe brother! 👊🤙
You are totally correct!! Awesome power, like a tractor. It wasn’t cheap my friend. $8500 in parts. But man does she ride!!!! Thanks for watching!!
Great video, I used to ride KDX’s in the UK, mainly trail riding. First was an E2 ,then a H2 and the last and best being a KDX220.
Neatest kdx I've ever seen I own 1 myself and they still my favorite
They are so much fun!! Thanks so much for watching!!
Thats so sick!
Thanks for watching Josh!!
Looks sick. I'm trying to fix my 2001 up after being in storage for over 15 years.
Nice job on the restoration. I've read that Lectron will shave the top and one of the screws for KDX applications. I restored 2 of them too - great bikes. Google KDX restoration and mine's the first pic.
Thanks for the comments. Googled it!! Very nice looking KDX, absolutely love it!! Great job!! Thanks for watching and great work!!
Fast forward a couple years to 2023+, the new Lectron Billetron Pro Series carb fits SIGNIFICANTLY BETTER along with the Lectron Billetron Long Body Adapter (+$30) and the longer Boyesen RAD Valve intake/reed cage or stock intake manifold with the thicker Moto Tassinari VForce4 reed cage behind it. The carb is more adjustable, far more advanced, and installs almost perfectly vertical before it touches the frame crossmember... It's the best thing for a '95+ KDX200/220, but costs double that of a brand new GENUINE Keihin PWK35 Air Striker carb - avoid the $40-$190 forgeries/fakes/knockoffs... The original carb on this guy's documented project really most likely just needed a replacement genuine OEM Keihin jet block gasket, which the OEM manufacturers' parts diagrams never even show, but ti's behind the tamper proof torx screws in the float area. Any leakage and the jetting will never be satisfied without replacing this formed o-ring gasket.
Great video man!
Thanks for watching!!!
Great build. Thanks for sharing! #kdxnation
Thanks so much!! Appreciate it!!
Awesome Build!!!
Thanks for that!!
Amazing build, amazing video 😁😁😁
Killer build!!
Thanks Daniel!!
@@LoveFirstWorld Hey, what front and rear fenders are these?
@@daniellindstrom9002 Front fender is a stock 2005 KX250F. The rear is Maier. maier-mfg.com/dirt.html.
Would you happen to know where the number plate on the original forks came from?
Nice video guys. Awesome bike. I think I may try to find a KDX project bike. Something a little different from the normal mx bike.
Killer ride! I see you used MotoCal for you graphics. I sent them a pic of your ride and asked if they could help me replicate as I couldn’t get the correct theme to load. They said if you could share your order number with me they could duplicate. My son loves the graphics and wants for his 1998 KDX project.
They didn't give me an order number... If you'll give me your email address I'm happy to forward to you what I have. Thanks!!
@@LoveFirstWorld Thank You but he figured it out and designed his own.
I have an 05 RMZ/KXF Front end to go on my 04 KDX 220, It didn't really seem like you had too many problems with the swap. Is there anything I should look out for? Awesome Build!!!
Maybe a short follow up video regarding your overall thoughts on the performance improvements. Anything you were disappointed in? How does it compare to a out of the crate modern woods machine? You seem to be a skilled rider. Thanks for doing the video.
I rode a KDX for 20 years (while my kiddos got new 🙄) and recently was able to buy newer for me.
For the record, the account reads “Holly” (my wife) but I am Shawn.
Thanks for that, I'll try to do a follow up. The only real difference from the KDX to a modern machine, I also have a 2020 YZ125X, is the riding position. The KDX makes sensational power, but does sign off on top a bit, unlike the 125X that has excellent overrev. Thanks for watching!!
Great video
Now I gotta get one
Had KX500 worked
I hope I can Handel a kdx
To make it even better, this bike should put some protections on the sides of the frame so as not to break the paint when wearing boots so it better preserved the frame.
resro the bike is top.
Good restoration.
Powder coating works well along with guards 👍🇺🇸
Nice project , you should have sent the bottom end cases out and had them vapor blasted but all in all nice job love the KDX bikes
Always something more to do... Thanks for watching!!
Awesome bike and good work. Great woods bikes
It's so much fun!! Thanks for watching!!
This is awesome just earned a new subscriber 🔥 I really want a kdx but they just don’t come up often
Be patient, it'll show up just keep looking!! Thanks for watching!!
Hi from 🇬🇧 I Bought a 96 KDX 200 off ebay 15+ years ago, sold it after a year 😢 Been thinking of a brand new bike of some description but, after watching Carson Browns recent upload about his KDX, I've gone down a wormhole looking for KDX builds 🤔
I also got inspired by Carson Browns KDX but here in Spain there is only one listed for sale in the whole country atm, an 02 KDX 220 not in the best shape and the guy is asking 2450€ which seems too expensive to me specially for the condition the bike is in, for a bit more you can get a used but newer Beta 200 rr which has better components, better handling probably but not as cool looking imo hahah cheers from Spain.
When you say “weapon” you ain’t kidding. That thing could very well kill someone!
HA!! Thanks for watching!!
Parabens, otimo trabalho, 2t e muito divertido tenho uma DT200r, KDX e um sonho.
Thanks for watching!!
I've got 1991 kdx200 goes nuts love it she is called kULPRIT
Love it!
Awesome Build.....Got me thinking....HaHa!!!!
Thanks for watching Mark!!
I feel like the KLX300R is the 4 stroke modern analoge to the KDX200. 2 stroke VS 4 stroke is an apples to oranges comparison, but having ridden both they are pretty similar in wheel to ground performance under 40mph.
Edit: Y'all seem like some cool guys. I'd like to hang out in yalls garage and drink a few beers.
Thanks for that!! Interesting comparison, haven't ridden the new ones, though your probably right. We had fun doing this build and it's a great bike to ride!! Thanks for watching!!!
Unfortunately, the KLX300 has a CV carb
Awesome! I'm doing a simular build with my 93 kdx200.
Very nice! We really enjoyed it! Such a fun bike!
How much do you have in the bike all together?
You can find them reasonably priced. However I had about $9000 in this one all in... That's a lot of upgrades to get her where she is that aren't cheap!! Thanks for watching!!
Great vid dude. I am so confused by the differences between kx and kdx frames and between the years. I have a kx250 from that vins as a 1992, but looks so close to this kdx frame only the bash gaurd loops under engine are diff. And to make all my confusion worse the previous owner put a kdx200 engine in it.🤣 So kx frame, kdx engine.....and they all look so similar.
Wow that sounds quite interesting. Good luck with it!! They're so much fun!! Thanks for watching!!
@@LoveFirstWorld thanks dude. It runs and rides already just gotta clean it up and refresh brakes and suspension. Seems like it is gonna be a blast but time will tell if I like the 2 stroke yank or not.
Great video. I’ve watched it a few times now to get some ideas. I have a completely stock low hour KDX 200 from 2006. Street legal. It’s a great bike and keeps up with the latest KTM‘s and Husqvarna‘s. I’d like to do a few upgrades. Any additional thoughts/resources you could share on the fork swap would be greatly appreciated. I’ve read dozens of posts on the KDX riders blog for guidance and the advice is from soup to nuts depending on the years. Hearing from someone like yourself who has roughly the same year KDX would be really helpful.
Hi there!! It was fairly straight forward. I ordered them on eBay off an "06 KX250F. Had the stem pushed out of the original lower triple clamp from the KDX into the KX lower triple clamp at a machine shop. And it literally bolted right up. There is slack in the upper triple clamp between the stem and the center hole. I just shimmed it with some thin pieces I had in the shed, works fine. Also, you'll need to change the hub out on the front wheel to a KX hub and the bike does sit quite high in the front, so I had to drop them down a bit to get the bike to sit properly. Good luck with your build and thanks for watching!! Let me know if this helps!!
@@LoveFirstWorld Thanks for the additional info. Does my original front brake caliper from the KDX fit on the KX fork? Or will I need to swap that too?
@@rminvest6276 Yes the caliper should bolt right up mine did.
7:24 I literally have that same shirt on but in black.
Funny!! Thanks for watching!!
KDX 200 was born a woods weapon.
Good video. Thanks for the tips. 3 years later, what are your thoughts on your KDX Mods?
Dude how tall are you? I'm a shade over 5-9 and I had to put a lowering link on mine to sit on it as you do yours. Great build! And guess what came in.... TODAY..... love it.
I run Klotz full synthetic snowmobile oil too. My friends are like wow what is that wonderful smell LOL
Hi Christopher!! I'm 6-1 so all good!! Oh yea Klotz smells so good. We need to make a Klotz cologne... LOL!!!!! Thanks for watching!!
@@LoveFirstWorld Haha IDK which smells better the Yamalube or the Klotz. Had the DT out today ..... ruclips.net/video/vz7naEpg1Mc/видео.html
Where’d you get the front fender and number plate?
Those are for a 2006 KX250F which is what the forks are off of. Thanks for watching!!
My 86 KDX 200 still the best bike in the Hoard might take $5000. to part with it though.😊
Agreed!! Thanks for watching!!
Is the stem from the stock triple clamp a direct fir into the kx250f clamps or is there any milling that needs to be done to press the stock stem in?
You have to have it pressed out and pressed in the KX lower triple clamp. There’s is a bit of slack at the top. So you’ll need to rig up a shim but no milling needed. Thanks for watching!!
Awesome video! Looking at one to buy now, its old and needs a restoration. What's the ball park cost to restore?
Listen to that classic KIPS rattle
Good stuff for sure!! Thanks for watching!!
Awesome project! I have one in the wait list becouse of a big problem with mine. I bought it with a plastic kit adapted to the frame… and having a deep look some days ago i figure put that the subframe was modified… i need someone to help me figuring out the subframe OEM measures, and maybe i could be able to make a blurpint of it. I need to start this project and i dont know where to find the OEM measures. Thanks🤟🏼
Know this is a old video but where did the plastics come from??
Most from Motosport.com. There’s are parts list in the notes. Front fender is 2006 KX250F and rear fender is from Maier. Thanks for watching!
What front # played did you use and did it need to be modified much??? Bought a 02 kdx200 and headlight was missing...Thanks
It's a KX250F plate because those are KX250F forks and triple clamp, not original, so they fit perfect. Not sure if it will fit original. Thanks for watching!!
Did you use the original stock front wheel for the inverted forks?. I just purchased a 2000 kdx200 and am wanting to do the same conversion. Curious as to what all you need for it. Thanks
Yes that is the stock wheel but the forks and triple clamps were from an 06 KX250F. So I had the wheels anodized and restrung and the for the front wheel I changed out the original hub to a 06 KX250F hub. Worked perfect. Any more questions let me know. Thanks for watching!!
Thanks
Besides pressing in the stem, was there any other mods you had to do with the upper tripple clamp to.the stem????
Currently looking at getting front forks, and a front wheel to go with it. No modding for the front factory wheel. Just grab a kxf front wheel bolt up and go
@@bryanhunter3143 There is a bit of slack from the KDX stem to the upper triple clamp. I rigged up a very thin sleeve to take up that minimal slack and bolted her up. Never had a problem.
WOAH! Did anyone else notice that the "KDX rattle" went away after the rebuild? Most of the time that rattle/piston slap/knocking sound doesn't go away after a rebuild, but somehow he fixed it! Nice going man! I hope you're reading this. If you are, what did you do to get rid of that damned knocking?
I know how hard it is because I just had my whole KDX 200 engine rebuilt by a good shop, top end and bottom end, and it has the same knocking sound before and after. As most people's KDX does. I wonder how you did that....e
Millennium Technologies did that... Highly recommend them!! Also the Lectron completely woke up the engine. Good Stuff!! Thanks for watching!!
That's just the powervalve man, completely normal 🤟
kips powervalve rattle normal
Man I just bought one and I was worried about that noise!! The bike is super clean as far as I could tell but it’s noisy
What is the rear fender from? I just started a 2001 220 build and want to do a rear fender like that…
It’s in the parts list but it’s Maier. Thanks for watching!!
How much was it for them to punch it out to a 225? I have mine apart right now. Before I rebuild I might go that route
Not sure what it would cost now, but it was $650ish a few years back... Thanks for watching!!