1991 KDX200

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
Post Reply
85' kid
Member
Posts: 45
Joined: 11:18 pm Apr 28 2021
Country: United States

1991 KDX200

Post by 85' kid »

Hi all, I have just recently acquired a 1991 KDX200, and have just got it running. It sounds good and shifts smooth, but when I start it up, the water in the radiators goes straight to the over flow tank, and out the overflow tank onto the ground. When its running the overflow tank looks like a jetted tub it is super pressurized, I thinks its the head gasket, but I want to hear some other thoughts on that. Also am wondering what the stock bore and stroke is.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 1991 KDX200

Post by KDXGarage »

Yep, the system is being pressurized.

Did you replace the head gasket (or have it apart)?

66 x 58
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: 1991 KDX200

Post by SS109 »

I concur, probably head gasket.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
85' kid
Member
Posts: 45
Joined: 11:18 pm Apr 28 2021
Country: United States

Re: 1991 KDX200

Post by 85' kid »

thanks, and no I have not taken the cylinder or head off, yet. Do you know what the sock hp, torque, and top speed is ?
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 1991 KDX200

Post by KDXGarage »

stock HP is around 27 or so, top speed around 70 mph with stock gearing
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
85' kid
Member
Posts: 45
Joined: 11:18 pm Apr 28 2021
Country: United States

Re: 1991 KDX200

Post by 85' kid »

for the 91 ?
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 1991 KDX200

Post by KDXGarage »

89 - 94
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
85' kid
Member
Posts: 45
Joined: 11:18 pm Apr 28 2021
Country: United States

Re: 1991 KDX200

Post by 85' kid »

ok, another question, my 91 has been sitting for 15 years and the clutch is not disengaging when you pull the clutch lever. I think maybe the clutch pads are stuck but I'm not sure. What do you think
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 1991 KDX200

Post by KDXGarage »

Have you changed the oil?

Setting for 15 years is not the best thing for them.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
85' kid
Member
Posts: 45
Joined: 11:18 pm Apr 28 2021
Country: United States

Re: 1991 KDX200

Post by 85' kid »

yes,I changed the oil
Goofaroo
Gold Member
Gold Member
Posts: 531
Joined: 12:42 pm Sep 09 2012
Country:
Location: Edmond, Oklahoma

Re: 1991 KDX200

Post by Goofaroo »

Did you try to put it in gear when it was running?

They can be a bit stubborn sometimes but generally you can break it loose by putting it into gear with the clutch lever pulled. At idle if the bike dies when you shift into gear try a bit of throttle and shift up from neutral into 2nd gear.
85' kid
Member
Posts: 45
Joined: 11:18 pm Apr 28 2021
Country: United States

Re: 1991 KDX200

Post by 85' kid »

That's exactly what happened, I put it into gear while it was running (clutched lever pulled) and it died, ill try giving it a little throttle next time to brake it loose, Thanks
rob the snail
Member
Posts: 17
Joined: 10:25 pm Mar 03 2020
Country: australia

Re: 1991 KDX200

Post by rob the snail »

bump start it in gear
85' kid
Member
Posts: 45
Joined: 11:18 pm Apr 28 2021
Country: United States

Re: 1991 KDX200

Post by 85' kid »

Well I actually forgot that while filling the engine with tranny fluid I ran out so I filled the rest of the tranny with motor oil. So most of the tranny was filled with motor oil. So that's probably why the clutch was a little sticky, lmao. I forgot I did this so I recached out to you guys when the problem was my own stupidity lol
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 1991 KDX200

Post by KDXGarage »

as long as you got it going!
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
Post Reply