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1991 KDX 200 Rebuild

Posted: 05:37 pm May 25 2025
by Chadnutz
I purchased a 1991 KDX 200 about 3 months ago now. Fixed the clutch issue it had, then went for a 30 minute ride. I noticed an oil drip immediately after putting the bike back in the shop. The oil filler read empty, which scared me. I decided to remove the engine from the bike and plan on getting new seals and bearings. Does anyone have any recommendations or places i can search for parts?

Re: 1991 KDX 200 Rebuild

Posted: 10:22 pm May 25 2025
by KDXGarage
Welcome to kdxrider.net.

When reading the sight glass, did you have the bike straight up and down or on the kickstand?

Re: 1991 KDX 200 Rebuild

Posted: 10:32 am May 26 2025
by Chadnutz
Straight up and down. plus, when i kicked the bike, the level would rise and fall

Re: 1991 KDX 200 Rebuild

Posted: 01:28 pm May 26 2025
by KDXGarage
Do you have the transmission vent hose?

Is it leaking oil externally?

How long did you wait to check the oil level after the engine was running?

Re: 1991 KDX 200 Rebuild

Posted: 06:58 pm May 26 2025
by Chadnutz
Next day

Re: 1991 KDX 200 Rebuild

Posted: 09:02 pm May 26 2025
by KDXGarage
OK, the reason I ask is because it takes a while for it to all settle back down.

Re: 1991 KDX 200 Rebuild

Posted: 02:22 pm May 29 2025
by Chadnutz
I found a Tusk Racing seal kit on Ebay. Would that be an option?

Re: 1991 KDX 200 Rebuild

Posted: 02:49 pm May 29 2025
by bufftester
Where was the oil leaking from? I ask because the location of the leak will determine whether a seal kit is going to solve it or not.