KDXRIDER.NET

Ok here is the story as quick as I can give it to you…. I bought a 1989 KDX 200 just over a week ago. When I went to buy it, I knew it was going to need some TLC, but it was RUNNING! Anyhow, when I got there I test drove it around the block and shifted up and down through all the gears flawless, and started flawless. Nevertheless, I bought the bike (great price SINCE IT WAS RUNNING), got the bike home and started it back up… drove it around a little and then took the plastics off to start working on it (chain, sprocket, drain fluids, replace brakes, etc…) Anyhow, I ordered all the stuff, got it in on Friday and Saturday put everything on (chain, sprockets, fluids, brakes, exhaust springs & O-ring, and repacked exhaust). When I went to start the bike back up it kicked over on the 2nd or 3rd kick just like it did when I went to buy it. So as it cranked I let it idle for about 5 minutes (it did have some white smoke) as I put the bike into 1st gear the idle severely dropped to the point to where it cut off. So obviously the idle air screw needed to be adjusted which I figured I would do after I took it for a little spin check the new chain, sprockets, and brakes out. So I kicked the bike back ON (yes it came back on) and then I just gave it a little gas before I popped it into 1st gear. I then drove it around the farm for about 4-5 minutes and then as I did a turn on a logging road I had to walk the turn out and the bike died (guessing due to idle speed), however, when I went to kick it back on nothing would turn over. So after a few kicks I went to reach for the choke and realized gas was pouring out the overflow.. so I tapped on carb to get the float unstuck and it stopped flowing out of the overflow. Nevertheless, we could never get the bike started again the rest of that Saturday or Sunday. We tried everything, removing sparkplug, replacing plug, making sure it’s getting a spark, removed carb, cleaned carb, jets, and readjusted float, but still cannot get the dang thing to fire and it is frustrating the crap out of me… any help or similar experiences would be greatly appreciated. What do I do now? Oh and yeah the guy did say he had the top end rebuilt the last 6 months or so and have not rode it much sense (not if that matters or not!)

Did you kick it over several times with the plug out, to get all the excess fuel out of it, before installing the new plug?

I'll go with David. Sounds like it dumped a bunch of fuel into the crankcase, and badly flooded it.

Yes we did kick it several times with plug out (and we did it several times) ...any other thoughts?

Is the plug soaking wet ?

chances are the float may be stuck if its leaking out the overflow, what you could try is turn the fuel on to fill the bowl then turn off, next with a clean plug kick it over with the choke on & see what happens.

If it still wont start then remove & inspect the spark plug .....if it sparks but is wet then remove & clean the plug, kick the bike over to remove excess fuel.......heat the spark plug end up on a stove for a few seconds then quickly install while its still hot/warm & kick start without choke......if the bike fires up then keep it running & turn on the fuel & ride around ....turn fuel off & ride around till it al most dies then turn fuel back on....if theres a blockage this sometimes clears things out.

If the above suggestions don't work, I suggest that you pull the jug and take a look at the top end, check to make sure the power valves are aligned properly and not broken.

Don’t trust that the top end had been rebuilt. That is a common lie. An old bike like that needs the crank seals replaced, without a doubt. Check the reeds and the end gap of the rings (and replace them if it is too much). Take the flywheel off and remove the stator plate then sandpaper it where it contacts the crankcase. Corrosion there hinders the ground path of the spark current back to the ignition system.

Deleted i should have read youre whole post b4 responding

I agree with above

ok i got the float level right last night and no more overflow, however, im still having trouble getting the bike to turn over. I am going to try cornishwrecker220 suggestion this evening, and then if that doesnt work, go from there! What is throwing me off is that when I went to buy it it was running and starting right up, and I didn't change anything on motor and all I did and was replace brake pads, chain and sprockets, exhaust manifold o-ring, new manifold springs, and repack muffler. NOTHING i did changed the fuel displacement etc... so that is why I am completely lost... unless it is just straight up flooding out? But again, what caused it because it was running and starting fine when I picked it up.. I literally have rode the bike 15-20 minutes tops, including the test ride.. so what the heck?

When you say its hard to turn over do you mean the engine takes a lot of force to kick like something is binding or do you mean its hard to start?

You said you changed fluids was the tranny oil low when you bought it? If so you could have a bad crank seal.

i just mean that it is hard to start... and oil was not low at all and was fairly clean actually to my surprise

Could have got a spec of trash in the carb that hung the float open.

'New' plug doesn't mean 'good' plug, I think we may have all been there at least once.

check that the new exhaust packing hasn't blocked your pipe !

i tired both of cornishwrecker220's suggestions with no luck.... and about trying various new plugs, we did do that several times.. .im completely lost at what is going on... i just dont know what could have gone so wrong that it wont even start... because none of the changes I made would have caused this... I mean even starting and then going off i could work with. However, since its not doing anything I am just lost. The shitty thing is that it probably something very small or dumb that I am missing... any more suggestions?

You ever get it figured out?

put a fresh plug in, then try again. after 10-15 kicks, pull the plug and look for signs of fouling, or fuel flooding. if it's fouled, that's actually a good sign (jetting/ breathing issue) of something that is off a little.

then pull hte stator cover and rotor to make sure the shear key on the crank shaft isn't broken.

make sure the entire intake (airbox, air filter, carb, reedbox, intake runners, exhaust pipe, arrestor) is not clogged with a mouses nest, paper towels, etc <--- it doesn't take much to prevent a two stroke from starting.