1994 KDX200 Problems - Low Power, Oil Leak, Hard to Start

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
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BigO1980
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1994 KDX200 Problems - Low Power, Oil Leak, Hard to Start

Post by BigO1980 »

I recently rebuilt a 94 KDX200 from a box full of parts I got from a guy off marketplace. It was a combination of me and a local mechanic that finished off the build after I ran out of time. Everything is all back together now and the bike runs, but I'm experiencing the following problems:

- Hard to Start, the air filter and carb are spotless so I do not believe it's either of these
- Will not idle without throttle, adjusting air and pilot screws does nothing
- Compression feels low even though piston and rings are brand new and cylinder is fine, very easy to kick over
- When riding through the gears, power is low. it will rev high but engine is not delivering nearly the power it should be
- black oil leaking from exhaust port. all of the correct gaskets and washers are in place between the exhaust and cylinder
- black oil leaking from crankcase overflow

I'm concerned that I have a crank seal issue, but wanted to check with others to see if there's anything else I should be doing / checking before I resort to taking the entire engine back apart to look at them.

thanks!
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SS109
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Re: 1994 KDX200 Problems - Low Power, Oil Leak, Hard to Start

Post by SS109 »

Please don't double post the same question in different subforums. I'm going to close this one and leave the one in General Discussion to get as many eyes on it as possible.
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