Rebuild time! (Crank seal failure) ((Questions))

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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p.caudilljr
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Rebuild time! (Crank seal failure) ((Questions))

Post by p.caudilljr »

I acquired a 96 kdx 200 about 3 months ago and have been going through the neglect of the previous owner getting it running. Got to a good point I thought and did a camping/riding trip to Fort Sage OHV near Doyle CA and the bike was phenomenal, super fun and very capable. Put it in the garage for about 3 weeks then decided to go on a little ride last weekend and was having a bog from idle to a little over 1/4 throttle. Almost like I needed to downshift. Thought it was elevation/jetting related since I was going from about 5000 ft to 8300 ft. Got back home and realized heavy smoke from the exhaust and I'm pretty certain it's pulling transmission oil through the crank seal 😕

Since splitting cases is the way to tackle this, what should be ok my list of things to replace while I'm there? I would like to not have to worry about anything other than regular maintenance for a bit. Thinking might as well do top end too.
So far I have this stuff on the list:

-crank bearings
-tusk engine oil seal kit
-inner clutch cover gasket
-tusk/wiseco pro-lite piston and gasket kit
-tusk clutch kit with heavy duty springs
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ss109
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Re: Rebuild time! (Crank seal failure) ((Questions))

Post by ss109 »

Before doing any of that please do a leak down test to know for sure. Test not guess!
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Re: Rebuild time! (Crank seal failure) ((Questions))

Post by KDXGarage »

Welcome.

Vacuum and pressure test to check the engine BEFORE tear down.
Thank you for participating on kdxrider.net. :bravo:
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