1991 KDX200 issues.

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1991 KDX200 issues.

Postby Weebs » 12:34 pm Jan 25 2006

I recently purchased a 91 Kawasaki KDX 200 for a song and a dance. I really have enjoyed it when I've had a chance to ride it. But alas, as with all used bikes we end up paying for the mistakes of others. Below I have listed the problems/issues I'm having and I'd really enjoy input about them.

1) The bike is extremely load. I had a 86 kdx200 a couple years back and the bike was very quiet. My buddy has a 03 kdx220 and it's very quiet. Mine sounds like the muffler has been repacked pourly. My question is... Would it be better to just pony up the cash and get an aftermarket pipe or try and repack the exhaust myself.

2) Before getting the 91 KDX I had been riding the 86 kdx200. The 86 seemed to have more power at the top end. I attribute this to a problem with my 91. It seems to get up in the powercurve and never seems to hit the powerband. Also it is tough to wheelie. What are some reasons this could be happening? here are my thoughts.
a) There is no chain roller on the bike and the sprocket has been worn down (being replaced). Maybe the chain was slipping. (I really don't think this was the issue)
b) The air filter is really clogged and no air is entering the airbox. (Could be, but I'd think I'd notice it all the time)
c) Bad sparkplug (bike starts fine so I'm not sure on this one)
d) ??? (this is where you come in )

3) Do anyone know a good online retailer for dirtbike seats? I really liked the gripper seat I had on my 1999 yz250. I'd love to get one for the kdx. I have only found one on Ebay...

Any help will be appreciated. Thank you for the help.
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Postby kdxquebec » 12:56 pm Jan 25 2006

Hi and welcome to the site.

1- do you have the stock silenser? Try to repack and see (almost free)

2-Maybe the power valve system is not working good.Be sure it works ok before search everywhere. All you need is here.....

http://www.geocities.com/a57ngel/moto/kips.html

Do you have a factory service manual? Change the sparkplug and clean air filter.

Where the roller you are talking about is located?

Give us news :grin:
Last edited by kdxquebec on 12:59 pm Jan 25 2006, edited 2 times in total.
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Postby m0rie » 12:57 pm Jan 25 2006

I'll bet you have a combination of low compression from a worn piston and rings, muffler that needs to be repacked and jetting that is not correct for your altitude. My 89 KDX 200 was in much the same condition when I bought it 5 years ago. You should do a top end inspection and make sure the KIPS valves are working properly and assess the condition of the piston and rings. If you see a lot of blowby then your going to want to replace the piston to get the performance back upto snuff. Other things to check: Reed s. My 89 seriously had the stock reeds in it when I bought it. They were chipped and warped to hell. If they don't seal tight and have any chips or cracks they need to be replaced. You can repack the stock silencer. Another area to look at is the pipe to cylinder junction. There should be two orings and a copper crush washer on the pipe. Its common for there to be an exhaust leak there. Fresh orings and some silicon will seal up the junction and stop the airleak. Ebay is pretty much going to be your only source for a gripper seat for a E series (89-94) KDX. That is a good quality seat cover from what i've been told though. You should also take a look at the carb and post what your jetting (main, pilot and needle w/clip position) is.

-Maurice
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Postby Weebs » 11:02 am Feb 20 2006

Thanks for the replies guys. They really helped.

The power problem was due to the main jet adjustment screw almost being unscrewed all the way.

everything is up and running (i hope) so i'm ready to ride this weekend!

Thanks again guys!
1991 Kawasaki KDX 200
2002 Suzuki GSX-R 750
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Postby Colorado Mike » 01:09 pm Feb 20 2006

Yeah, gotta watch those main jet adjustment screws.
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Postby cicone » 12:31 pm Feb 21 2006

>|<>QBB<
Colorado Mike wrote:Yeah, gotta watch those main jet adjustment screws.



Huh?
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Postby GhostRider » 03:16 am Apr 19 2007

??? main jet adjustment screw
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Postby 2001kdx » 01:28 pm Apr 19 2007

6mm socket so I remember.
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