Jan's shed

Show us that box of bits in your shed!
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JanBros
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Jan's shed

Post by JanBros » Thu Dec 10, 2020 1:59 am

new topic where I'll keep track of all stuff I'm doing

first I bought a new toy, off course it's green and a 2-stroke 8)

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bought it as a project for only 600 euro. without papers.
already bought a KMX200 frame with papers, so if I decide to put it on the road, the KMX number is going on the frame (apparently a KMX200 and KDX200 have almost nothing in common. totaly different frame/engine). possibly I'll only use it on MX-tracks. specificaly wanted the KDX200 because it's got almost the same power as a KX125 but has the easy driveability (widespread torque) of a KX250.

bought it to improve my off-road skills to become better at moped-MX :mrgreen:

ran almost immediatly after cleaning carb, so that's the good news. teared it appart and opened the engine, sadly KIPS valves are broken (seem to be crap, BDK makes steel ones, 145 £) and 2 cracks in the cylinder. rest is fine. don't what to do with the cylinder yet : sleeve or just use it as it is (filling the cracks a bit so the rings can't catch them). Don't think welding would solve it permanently.

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My ultimate goal is to die young as late as possible !

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JanBros
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Re: Jan's shed

Post by JanBros » Fri Dec 11, 2020 10:36 pm

since the KX500 is sold, decided to use the rolling frame from that project for my own KR, so that if I crash again (which probably I will some day :mrgreen: ) I can only damage/destroy an already non-original one.

RGV swing arm, R6 rear shock, ZX6R front

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bracket's for the KX500 engine need o be removed again

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gonna cut off the entire section and weld in a new one, I have an alu beam with the exact same size

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the weldded-in plate where the rear mount was bolted on clears the engine, so I'm gonna leave it in

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was afraid it would be hard to weld in the corner due to minimal space with the beam in place, so I first welded in some blocks, so the front weld could be moved to the middle

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bought the frame years ago on ebay-uk as it was already prepared (not fully done) to fit the KX engine, but for posting I told him he could cut off the rear frame. I welded it back on, but as it was just as a track bike, didn't put much effort into it and the position wasn't very accurate.
have one more adjusted rear/side unit, so decided to make the rear frame bolt-on, so in the future I could make a new rear subframe and use plastics from another bike, to save/not ruin more KR1-parts
made some parts to weld into the subframe-beams

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difficult to get the subframe back into the exact some position, it's slightly up at the rear

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My ultimate goal is to die young as late as possible !

Frunobulax
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Re: Jan's shed

Post by Frunobulax » Sat Dec 12, 2020 7:51 am

Looks promising! 8)
Cool to have skills and tools for welding.

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Re: Jan's shed

Post by stevo135+ » Mon Dec 28, 2020 6:52 pm

Nice project bike!
I have a KMX 200 myself in boxes in the shed that's supposed to be my off road green lane bike when I've put it together. I've also got a re-plated cylinder with a load of porting work and head modifications by BDK racing. Not so ideal for an off road green lane bike but I didn't think of that.

Anyway I just saw the pictures of your KDX cylinder and that's a very strange exhaust port design isn't it?

The small cut out at the top of port is not something I've ever seen before, I wonder what the reason is for it?

And secondly 5 exhaust ports? That seems excessive but maybe its the ideal set up for a high performance engine? I'd love to know how having 5 small ports compares to the design from h***a, Suzuki etc where there's just a huge bridged port instead and no auxiliary ports used?

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JanBros
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Re: Jan's shed

Post by JanBros » Mon Dec 28, 2020 10:13 pm

KX500 also has the 5-exhaust-port lay-out.
in the small cut-out on top of the main port is a valve. haven't studied it yet but it probably opens together with the KIPS.
My ultimate goal is to die young as late as possible !

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