'91 KDX 250 Build thread, all advice, tips, criticism welcome

[PacificNWRider]

Apologize if there is multiple pics was having some troubles getting them posted.

[PacificNWRider]

I can't speak for others on here, but I like seeing the pics and details from bike builds. The KDX250 and 200/220 are very close but do have some unique details from each other. Share away, I can say with pretty high confidence that nobody on here has ever complained about sharing moto pics!

Ok, good to know thank you, I will work on getting some more stuff together to post.

[PacificNWRider]

Thanks for the update. Though disassembled for many years, I actually own a 1991 KDX250. It is definitely a fair bit different than the 200/220.

There are a good many here that read without replying. Keep up the good work.

Well shoot, what do we need to do to get that thing back together ?? Thank you for the encouragement

[PacificNWRider]

Great rebuild thread.

Nice build! Bike looks great!

Thank you very much, i will try to get some more of it posted.

[KDXGarage]

Thanks for the update. Though disassembled for many years, I actually own a 1991 KDX250. It is definitely a fair bit different than the 200/220.

There are a good many here that read without replying. Keep up the good work.

Well shoot, what do we need to do to get that thing back together ?? Thank you for the encouragement

More than a miracle!

The pics are now working. It looks fantastic!! Congratulations on seeing your hard work come through for you!

[PacificNWRider]

Well, after what I just went through I kind of feel like a miracle worker, ha.. Looks like i'm on the other side of country, but heck, I am willing to help anyway possible. Do you need parts or help with assembly? I've been known to do some pro bono to help someone out.

Thank you for the kind words, it was a good deal of work... and now... its time to ride it like it owes me MONEY, because it does!

[KDXGarage]

Nah. That's OK. I appreciate the offer, though.

Yours tuned out great!

[Pressingonward]

Love the look of this bike! I wouldn't worry about the slight mismatch between the number plate and the fender

[VTMTcowboy]

Beautiful build! Looking forward to the ride reports.

[PacificNWRider]

Love the look of this bike! I wouldn't worry about the slight mismatch between the number plate and the fender

Thank you, yeah, I think I am going to just leave it be for now, summer going way too fast, thank you for the feedback

[PacificNWRider]

Beautiful build! Looking forward to the ride reports.

Thank you! So far so good, trying to put together some good posts in the coming days, trying to get some GoPRO footage for everyone.

Seems to ride like a cadillac, very smooth suspension, I have some adjustments to make, Im at 180 / 6'2" It seems to be in a pretty good spot so far out of the gate.

The bike is running very very nice. First kick, crisp response! I haven't railed it yet, but I have ridden it moderately and the bike is an animal. I can definitely see a problem getting out of 2nd gear on the trails, by the time you are on the pipe in second, you better have some room....Will be spending some time getting the sprocket sizes figured out.

Will definitely have some more coming when I can, lots of trips planned for the last month of summer, but I will try. Thank you for the input & compliments!

[cb_swift]

Hey man nice build. I just picked up a 92 250. I dropped the motor off for a full rebuild. I’ll be working on all the rest. Other than the motor mine is in great shape and all original from what I can tell. I’m doing a refresh/clean up for a rider not a museum piece. Can you link info on that tool to remove dents from the pipe and info on where to get factory decals?

[Ricardo.Giacom]

Got a new to me 1991 KDX 250 because it was too good of a deal. No such thing and I know this. My dream of building the ultimate PAC NW trail bike took control and made me bring this bike home. In my eyes the perfect bike would be a combination of a 4T & a mid 90's 2T I believe that the KDX250 is that bike

Now I got my work and learning cut out for me. Going to try and bring everyone along on the ride.

Here is the bike on the way home.


My initial findings on the bike were: missing right gas tank plastic, some groovy Blue Bigfoot stencils (maybe someone will recognize it), some dents in exhaust-though nice pro-circuit pipe/fmf silencer, terrible chain & sprockets, non stock headlight and rear fender, shock seals blown & possible more damage, terrible tires. Needs new levers, brakes completely gone through... yeah I need to go through this entire bike. Old nasty air filter, and dirt and sand in the airbox..... The carburetor looked very clean, the overall bike was pretty clean.

It had very low compression, my bet is all the dirt and SAND in the airbox, either that or the NON MIXED GASOLINE IN THE GAS TANK. and the kickstart wasn't catching, but when I looked over the bottom of the frame and there was not a dent or ding on it, I thought...this bike hasn't been ridden THAT hard?. No evidence of 2T goo all over the cylinder and silencer. The swing arm linkage seemed fairly decent with a very small amount of play, and the bearings in the stem were tight although not perfectly smooth.

All in all, I was going to rebuild any bike I bought from the ground up, So yeah I brought it home... Let it begin...

Today 2025/01/02 I start building a KDX 250.
I need someone to give me a very reliable VIN code calculator because I want to know what year the motorcycle really is.

[bufftester]

10th digit of the VIN L=1990 M=1991 N=1992 P=1993

[KDXGarage]

https://www.faxvin.com/vin-check/year-chart

R = 1994

S = 1995 (Europe had a 1995 model I believe)

[Ricardo.Giacom]

https://www.faxvin.com/vin-check/year-chart

R = 1994

S = 1995 (Europe had a 1995 model I believe)

Is it safe to enter the VIN number on that website? I'm afraid something bad will happen to my motorcycle.

[KDXGarage]

Just look on your VIN and count to the tenth digit. That digit is the year code in a VIN (car, truck, motorcycle).

M, N, P, R or S

That is assuming a USA model. If you have a KDX250 that is not a "D" model, it may have a "Frame Number" instead of a VIN. UK models came with a frame number.

If you have 17 digits, then it is a VIN.