1) Q: The KDX250 has inverted forks, does this mean more maintenance ?, fork seals etc
A: No
2) Q: The 250 has a perimeter frame, does this mean that the frame is much more advanced the the KDX200. Will this help on the whoops.
A: The perimeter design is more advanced than the '91 200, but the KDX250 uses heavier material than the KX250. The KDX250 has slow steering geometry which is generally better in the whoops, but the stock suspension needs a little work on both bikes. In stock trim, neither bike will handle whoops like a good MX machine.
3) Q: How much heavier is the KDX250 over the KDX200.
A: Approximately 20 pounds actual difference; about 250 for the KDX250 and 230 for the '91 KDX200. Not sure what Kawasaki says.
4) Q: Do they both have the same brakes, I had a real short ride on 200 and the brakes are weak compared with a DR650 (my dual sport bike).
A: I believe they do have the same brakes. Kawasaki brakes are notorious for getting air bubbles that are hard to bleed out without removing the brake line from the bike to straighten it out. After a complete service, both bikes will have acceptable but not great brakes.
5: Q: Which engine is more durable ?.
A: Both are excellent for durability. The 250 is basically a mildly tuned '88 KX250.
6: Q: Does the 250 make alot more power than the 200.
A: Yes, especially down low. Both bikes benefit greatly from rejetting, pipes and a few other mild mods. The 250 has a very heavy flywheel weight.
7) Q: Did the latter KDX200 1993+ receive the same frame as the 250 or a lighter one?
A: Lighter one in '95 for the 200; completely different than the 250.
8) Q: I believe that Kawasaki nickle palted the bore's. what is the impact on this, I was told 300 dollars to re-seleve the cyclinder.
A: Both bikes have a 'nikasil' coated bore. Unless it is damaged, this is a good system. I belive the charge to recoat the bore (if needed) should be less than $300, unless you have to pay for labor also.
9) Q: What are the weak points of these bikes ?. What shoudl I look at in particular.
A: Both bikes are good trail bikes and entry level enduro bikes. Both bikes need stiffer springs and a fork revalve. Stock, the 250 is a sluggish handler and heavy for a 250 two stroke; You can set it up to handle better but it will always be heavy. The 250 is a 5 speed, while the 200 is a six speed. A poorly set-up 250 can be a pig, but the bike can be transformed with a little work.
The 200 is a fun bike to ride, but if you ride in the mountains or hilly areas the extra power of a 250 is a big plus for a 200+ pound rider.
Buying used, both bikes are likely to have worn wheel bearings, linkage bearings and gummed up powervalves. Ask if those things have been serviced. Ask if the bikes have been rejetted. Ask if the forks can be fixed.
Disadvantages of the 250 is that side panels and radiator shrouds are not available.
10: Is there a big difference in the range that each bike can travel on one tank, are the tanks the same size.
A: My '90 200 had a 3.2 gallon tank and would go about 70-75 miles after rejetting. My '91 KDX250 was measured at a 3.6 gallon tank (manual says 3.3 gallon) and it would go about the same after rejetting. Both bikes will go as much as 100 miles if you gear up and ride a dual sport road ride, or as little as 50 miles if you are slogging through heavy mud all day.
11: Q: I am 5'11", 205 lbs. What will suit best ?.
JMHO, but if the 250 is well set up, I would look to it, but the 200 is also a fine choice.