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Old 02-18-2014, 01:33 PM   #1
tHEtREV OP
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Joined: Apr 2007
Location: Middle Park, Brisbane, Australia
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Question 84 KDX200 with a 72mm piston?

I got a 84 KDX200 as a long term Vinduro project last week.

It is in very rough condition, no plastics, seat or tank, a stuffed piston and the big end has thrown its bearing.

I have been pricing parts before I start the rebuild in April, new rod, bearings etc were pretty easy to find, and I even found a piston, but on inspecting the cylinder I noticed it was an iron bore instead of nicasil (sp?) or chrome.

So I did the sensible thing and measured the piston.

I had found some dimensions for an 86 model piston so I thought I'd see if the measurements were close, so I was looking for a 66mm bore (same as the 83 to 85).

The piston measured 72mm across...

The other dimensions I had were way out (top of pin to edge of crown, and pin diameter).

I cleaned up the piston and found it has 71.94mm stamped in the crown, so my measurements are not screwed up, so I double checked I didn't have a 250 (70mm bore), but the compliance plate says its a 84 KDX200b (I thought they were still an "A"), and the engine has the DX prefix, and the barrel says 198cc.

So does anyone know what the PO has done to the engine?

Was there a common 72mm big bore kit for these old bikes?
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tHEtREV screwed with this post 02-18-2014 at 07:06 PM
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Old 02-19-2014, 02:20 AM   #2
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I stuffed up on the title of this thread obviously, but I think I found my answer.

I was thrown of track because the measurement I had found were wrong by the looks of things, (they stated an 18mm pin, where it should be 16, so I have no idea what the piston they measured was out of ).

The bike has had a 240 "Big bore" kit installed.

The kit is apparently a L.A. sleeve liner, with a Wiseco piston (my piston was a Wiseco).

Piston is a W969PS.
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Old 02-19-2014, 07:41 AM   #3
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84 KDX,should be a spectacular build. You''l be selling that pedestrian Gas Gas in no time.
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Old 02-20-2014, 02:22 AM   #4
theMISSIONARY
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Location: Devonport Tazmania
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your going to love those Vibrations tREV
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Old 02-20-2014, 01:25 PM   #5
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Its only for vintage enduro so it is not a concern.
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Old 02-20-2014, 10:11 PM   #6
theMISSIONARY
hunting and riding!!
 
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that just adds that the experience......but does it have a Race Pipe
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Old 02-20-2014, 11:48 PM   #7
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It will have to...

A DG pipe is the cheapest option.

But I may still just use this bike as a parts bike.

So much is missing from it, and an 83 model went for $130 today on ebay, it was complete but in need of a major rebuild.

So I might just keep my eye open for a more complete bike in the next few months.
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Old 02-21-2014, 05:10 AM   #8
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i see old habits die hard.....

PS let me know if you see any standard KTM 530Exc mufflers
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