I picked up a cheap 2000 kdx 200 last summer that was headed for the scrapheap with a view to giving it a new lease of life. Since then, i have rebuilt it from the bottom up, engine work carried out included:
- -all new oil seals
-all new bearings
- new conrod\re-balanced the crank
-new gaskets
-new piston + rings
-cleaned + timed the kips
-replaced any broken\worn parts
-new stator coil, ht coil and cdi
- - engine is making 150 psi
-kips is definitely timed correctly, checked by removing exhaust and looking into the cylinder, also removed the inspection cover for the kips gear and it moves as it should when i rev the bike at idle
-completely cleaned carb and rejetted to 156/45, also checked the jet block gasket which is in good shape
- reeds are not chipped\damaged and seem fine
- tyres have good tread and run 12psi front 10psi rear
- cleaned and oiled air filter
- re-packed silencer
- all new fluids
I know the clutch could do with being changed, but ran out of money and thought i'd do it at the next service (springs + plates were out of spec and the basket is grooved), but surely this wouldn't account for that much power loss?
Also, the sprocket combo is 13/50, but surely that would give it more 'snap' so to speak?
I plan on replacing the clutch and filing down the grooves on the clutch basket, i'll also replaced the sprockets + chain (chain is a bit stretched and at max. adjustment) and revert back to the stock 13/47 gearing, but can't see that this will make that much of a difference. Other than that, all i can think of is an over-oiled air filter or over-packed silencer, but i'm really clutching at straws with those!! Anyone got any ideas that i may have missed?