kx 85 rebuild

[locko90]

I have decided to do this kx 85 up ...

this is my first attempt at fixing up a bike so I might make a few mistakes.. let me know if I have
anyway im gunna try get it back to good running condition and get it looking good for as cheap as possible.

here's how it was after a wash yesterday, it doesn't look to bad, but looks can be deceiving...


after a quick wash with the hose I started taking the plastics, seat and tank off..



then off with the muffler, front forks and wheels I gave the chain a quick clean with degreaser a tooth brush and a cloth as well.




after that I started with servicing the forks first... I cleaned behind the fork seals with a thin piece of plastic, fork seals where in good condition but where leaking... just scraping the grit out from in there stopped the leak then packed with grease and replaced dust seal.





after that I replaced old fork oil see if u can spot the new stuff lol.



that was as far as I got that day, ill update when I get more done, if u have any suggestions let us know,

 

[locko90]

spent the whole day today cleaning plastics, wheels, pipe and forks. it was a long process, but its going to make a big difference especially if I end up selling the bike..

the plastics were old faded and stained I managed to clean them up pretty good with just a scourer, steel wool and soapy water... I ended up getting some fine steel wool to smooth out the scratches and give it that polished finish, heres a vid of how I cleaned the plastics...

[video=youtube;v4odTV5WtDk]https://www.youtube.com/watch?v=v4odTV5WtDk[/video]

this black grime was all over the plastics.





with the pipe I just used steel wool and some old petrol I had, im going to have to get drill and a wire brush attachment to buff the badly rusted bits, but just using the steel wool has really started to revive this rusty old pipe!



should be able to get this pipe looking good as new :alc:

the wheels took a fair while to clean! hard to reach places... used a tooth brush, steel wool, petrol, and soap got em looking awesome!!





well that's pretty much everything cleaned looking good



time to repack wheel bearings...

 

[locko90]

I just wedged a small flat head screw driver to get the wheel bearing seals out


then gave it a good clean and packed it with heaps of grease




seals back on all looking good

well that's all I got done today ill update with more soon!!

 

[my67xr]

Top job, it's looking pretty nice so far

 

[locko90]

thanks mate, looks like ive run in to a problem now when I checked the power valve arm today I noticed its out of alignment!!

who ever had this apart hasn't put it back together properly, and have no idea how long its been like this!


u can see that the power valve arm is not lined up with the guide line. omg... people that cant find out how to do a job properly... hopefully it can be fixed..

any way I started to try and get the side cover off so I can get that power valve arm out and put it back to correct position... then I couldn't get the seized kick starter off... I ended up giving up for the day and just went and rode the pit bike around.. I sprayed the kick starter spline with wd-40 and just guna let it soak.

very annoyed about the power valve arm being in wrong position!!!! hopefully I can sort out getting that kick starter off and then putting that arm in correct place..

 

[locko90]

I just found this great tutorial on how to remove kick starters im not sure if my kick starter over laps the bolt but the tutorial looks promising, I wish I googled how to remove kick starter when I was working on the bike other day... oh well..

heres a link to the tutorial... Simple Kickstarter Removal - Pro Wrenching Secrets - Dirt Rider Magazine | Dirt Rider

 

[locko90]

I've had a few days to work on the bike this weekend, managed to get a fair bit done..

[video=youtube;wVsxN0Elx7s]https://www.youtube.com/watch?v=wVsxN0Elx7s[/video]
well heres a vid on the problem kips shaft it wasn't in the right position and was causing the power valves to not work properly..

got the seized kick starter off with some vice grips and wd40
took both cases off.
cleaned kips shaft
cleaned up case, governor and bearings with throttle body cleaner then added gear oil to bearings.

After that cleaned kips housing, then I put the kips shaft back in correctly using the alignment marks.



then I put the clutch cover back on, put the water pump propeller back in, radiator hoses back on set the clutch cable back up and slaped the kicker back on it!


since I got that kips problem fixed I ended up putting the bike all back together so I could ride it and see if it was running any better..

looking better

but when I was filling up the radiator there was a leak in the water pump cover where there was damage to gasket, so I got some gasket glue and am leaving it over night to seal the water pump case.

after that water pump case is sealed I will take it for a ride and see how she runs.