96 KDX 200 help
-
- Member
- Posts: 5
- Joined: 08:20 am Feb 06 2007
- Country:
- Location: Atlanta, GA
96 KDX 200 help
Just bought a 96 KDX 200 that's all stock. The previous owner told me it didn't run very well and hence I got it for a very good price.
Here's the problem - the bike won't idle. I've got the throttle stop all the way in. Also won't pull cleanly to redline. It's obviously loading up and rich (black spooge and fouling plugs), but I can't seem to figure out why.
Here's what I've done and checked so far -
Drained fuel tank and mixed fresh gas with yamalube R @ 32:1
Cleaned carb. Checked pilot and main jet for blockage. Checked all the circuits with carb cleaner to make sure they were clear.
New float needle and seat
Checked floats - they still float
Main jet - 155
Pilot jet - 42
Needle clip - middle slot
Air screw - 2 1/2 turns out
Float height - 16mm
Compression - 150psi
New NGK BR8ES (several )
Cleaned the air filter.
Checked for cracks around intake boot. Sprayed WD-40 around with bike running, but no change in RPM to indicate an air leak
Pulled the flywheel cover to see if there was evidence of a crankshaft seal leak, but I don't see any black stuff there. I don't appear to be losing any transmission oil either.
Looking through previous posts, it appears I'm pretty close on the jetting. I started jetting down on the main jet today just to see what would happen. The bike ran a little better for every size down I went. When I got to a 138 the bike pulled cleanly through to redline. I'm sure if I go with a smaller pilot jet, I'll get it to idle. I'm afraid I'm headed down the wrong road by jetting that far down. A 138 main jet seems to small to me. I suspect I would just be covering up a problem. I'd rather fix it correctly.
I've exhausted my knowledge. Anyone have an idea?
Here's the problem - the bike won't idle. I've got the throttle stop all the way in. Also won't pull cleanly to redline. It's obviously loading up and rich (black spooge and fouling plugs), but I can't seem to figure out why.
Here's what I've done and checked so far -
Drained fuel tank and mixed fresh gas with yamalube R @ 32:1
Cleaned carb. Checked pilot and main jet for blockage. Checked all the circuits with carb cleaner to make sure they were clear.
New float needle and seat
Checked floats - they still float
Main jet - 155
Pilot jet - 42
Needle clip - middle slot
Air screw - 2 1/2 turns out
Float height - 16mm
Compression - 150psi
New NGK BR8ES (several )
Cleaned the air filter.
Checked for cracks around intake boot. Sprayed WD-40 around with bike running, but no change in RPM to indicate an air leak
Pulled the flywheel cover to see if there was evidence of a crankshaft seal leak, but I don't see any black stuff there. I don't appear to be losing any transmission oil either.
Looking through previous posts, it appears I'm pretty close on the jetting. I started jetting down on the main jet today just to see what would happen. The bike ran a little better for every size down I went. When I got to a 138 the bike pulled cleanly through to redline. I'm sure if I go with a smaller pilot jet, I'll get it to idle. I'm afraid I'm headed down the wrong road by jetting that far down. A 138 main jet seems to small to me. I suspect I would just be covering up a problem. I'd rather fix it correctly.
I've exhausted my knowledge. Anyone have an idea?
- Indawoods
- Creator and Founder
- Posts: 9951
- Joined: 09:59 am Jun 12 2003
- Country:
- Location: Midwest
Had that problem with my brothers when I built it. Turned out to be a clogged Pilot Jet..... replace it and see if that makes a difference....
*** Administrator //***
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
-
- Supporting Member II
- Posts: 1005
- Joined: 06:57 pm Mar 19 2005
- Country:
Sounds like a very weak spark to me. CDI box problem is what I suspect based upon your symptoms. You know someone with a KDX to swap out the box with for a "test" confirmation??
P.S. Check out coil/plug wire/ plug cap and associated wiring and grounding paths also to confirm they are within specs and tight.
P.S. Check out coil/plug wire/ plug cap and associated wiring and grounding paths also to confirm they are within specs and tight.
KTM 380EXC Mine
KDX 200 Mark's
TTR 125 L Wife's
KDX 200 Austin's
EC 300 Tyson's
WR430 Husky - mine
KDX 200 Mark's
TTR 125 L Wife's
KDX 200 Austin's
EC 300 Tyson's
WR430 Husky - mine
-
- Member
- Posts: 5
- Joined: 08:20 am Feb 06 2007
- Country:
- Location: Atlanta, GA
While I don't know anyone with a KDX 200, I do have a buddy with a KDX 220. So you gave me an idea. I swapped the carb from his 220. It fired right up, idled, and ran great. So, I guess the problem is with my carb.IdahoCharley wrote:Sounds like a very weak spark to me. CDI box problem is what I suspect based upon your symptoms. You know someone with a KDX to swap out the box with for a "test" confirmation??
P.S. Check out coil/plug wire/ plug cap and associated wiring and grounding paths also to confirm they are within specs and tight.
Now the question is what? I've replaced my float needle and cleaned the carb really good. I was able to blow carb cleaner through all the circuits. Guess I'll go back and do it again.
Indawoods - I know the pilot is not clogged as I can see through it. However, I guess it's possible there's some gunk in there I can't see that's restricting it. My buddy's 220 carb is running the same 42 pilot that I am. I think I'll swap just the pilot and see if that helps.
Thanks for the suggestions/ideas guys.
- Indawoods
- Creator and Founder
- Posts: 9951
- Joined: 09:59 am Jun 12 2003
- Country:
- Location: Midwest
ZACTLY.... same with my brothers....
I rebuilt his 3 times before I found some green crap in the pilot jet... I just replaced it vs trying to get it all cleaned out and possibly having the issue again.
I rebuilt his 3 times before I found some green crap in the pilot jet... I just replaced it vs trying to get it all cleaned out and possibly having the issue again.
*** Administrator //***
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
-
- Member
- Posts: 5
- Joined: 08:20 am Feb 06 2007
- Country:
- Location: Atlanta, GA
Well, new 42 pilot didn't work. Guess I'll try and find a 40 to see if that helps.
I checked the choke to see if it was possibly leaking fuel by, but that's not it either.
I don't know what else to do short of finding another carb on eBay.
Of course, I could switch carbs with my buddies 220 and hope he didn't notice
I checked the choke to see if it was possibly leaking fuel by, but that's not it either.
I don't know what else to do short of finding another carb on eBay.
Of course, I could switch carbs with my buddies 220 and hope he didn't notice
- Indawoods
- Creator and Founder
- Posts: 9951
- Joined: 09:59 am Jun 12 2003
- Country:
- Location: Midwest
Something is hallared, wallered or plugged....
Just get an Air Stryker from Ron at http://rb-designs.com
Then you be talkin!
Just get an Air Stryker from Ron at http://rb-designs.com
Then you be talkin!
*** Administrator //***
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
- fuzzy
- KDXRider.net
- Posts: 3437
- Joined: 01:29 pm Jun 18 2003
- Country:
- Location: Fredneck, MD
New RB carb would be great as in the long run you'll want RB's work anyway. Can get used carb on ebay, or maybe send him yours and let him look it over. Soaking the carb in Berryman's/hitting w/ air hose might do the trick as well.
'91 KDX 200 Project $300 KDX
'95 KDX 200 Project $600 KDX
'94 WR 250 Always a project
'95 KDX 200 Project $600 KDX
'94 WR 250 Always a project
- canyncarvr
- Gold Member
- Posts: 6943
- Joined: 01:07 pm Nov 05 2004
- Country: US
- Location: The Mythical State of Jefferson
IC is familiar with carb idle/adjustment problems. He found a speck of flashing crud in a lo-speed passage. That sort of thing will pass carb cleaner all day.
You're familiar with the line-up required for the needle nut cable retainer?
Get some guitar string clippings. Soak the carb in some Berrymans. Poke and prod the passages you can get to with those string ends. Soak some more, blow it out...al better.
...hopefully.
Looking forward to what you find!
You're familiar with the line-up required for the needle nut cable retainer?
Get some guitar string clippings. Soak the carb in some Berrymans. Poke and prod the passages you can get to with those string ends. Soak some more, blow it out...al better.
...hopefully.
Looking forward to what you find!
Consider the source
Using a perceived level of knowledge to boost my self worth.
Non impediti ratione cogitationis
bike profile: !clicky!
-
- Member
- Posts: 5
- Joined: 08:20 am Feb 06 2007
- Country:
- Location: Atlanta, GA
- m0rie
- Supporting Member I
- Posts: 2220
- Joined: 10:25 pm Nov 29 2004
- Country:
- Location: Crescent City, CA
I don't think the gasket that is under there is a replaceable part. Ron might be able to let you know if it is.
1989 KDX 200
2007 TTR-50E
2007 TTR-50E
- canyncarvr
- Gold Member
- Posts: 6943
- Joined: 01:07 pm Nov 05 2004
- Country: US
- Location: The Mythical State of Jefferson
Ron adjusts jet block height on older Keihins to match newer styles to make needles/clipping common between the two, so it's not like once it comes out it never goes back in.
..don't know what sort of sealing piece it has..an o-ring?
I'd wonder about the more common carbie problems before I'd invent new ones.
..don't know what sort of sealing piece it has..an o-ring?
I'd wonder about the more common carbie problems before I'd invent new ones.
Consider the source
Using a perceived level of knowledge to boost my self worth.
Non impediti ratione cogitationis
bike profile: !clicky!
-
- Supporting Member II
- Posts: 1005
- Joined: 06:57 pm Mar 19 2005
- Country:
I'd follow CC advice if I were you and Inda's advice if you have a small PJ plugged.
The tamper proof star screw can be removed (appropriate star wrenchs available at Auto Zone and Checker stores). I took mine apart 2 or 3 times and just reused the o-ring. Removing the nozzle piece gives you better access to a couple of internal passages.
The tamper proof star screw can be removed (appropriate star wrenchs available at Auto Zone and Checker stores). I took mine apart 2 or 3 times and just reused the o-ring. Removing the nozzle piece gives you better access to a couple of internal passages.
KTM 380EXC Mine
KDX 200 Mark's
TTR 125 L Wife's
KDX 200 Austin's
EC 300 Tyson's
WR430 Husky - mine
KDX 200 Mark's
TTR 125 L Wife's
KDX 200 Austin's
EC 300 Tyson's
WR430 Husky - mine
- canyncarvr
- Gold Member
- Posts: 6943
- Joined: 01:07 pm Nov 05 2004
- Country: US
- Location: The Mythical State of Jefferson
Berrymans!
Consider the source
Using a perceived level of knowledge to boost my self worth.
Non impediti ratione cogitationis
bike profile: !clicky!
- Mr. Wibbens
- KDXRider.net
- Posts: 4884
- Joined: 02:57 am Nov 07 2004
- Country:
- Location: Playing in the Poison Oak
- Contact:
Warning! This member tends to use sarcasm as a regular form of communication. If a post seems offensive, before you panic and fly off the handle, re-read the post and imagine it being said with a sideways grin.
((Bike Profile))
((Pics))
FIVE OUT OF FOUR PEOPLE DONUT UNDERSTAND FRACTIONS
((Bike Profile))
((Pics))
FIVE OUT OF FOUR PEOPLE DONUT UNDERSTAND FRACTIONS
- Mr. Wibbens
- KDXRider.net
- Posts: 4884
- Joined: 02:57 am Nov 07 2004
- Country:
- Location: Playing in the Poison Oak
- Contact:
No but here's the MSDS
http://www.berrymanproducts.com/Portals ... 200905.pdf
http://www.berrymanproducts.com/Portals ... 200905.pdf
Warning! This member tends to use sarcasm as a regular form of communication. If a post seems offensive, before you panic and fly off the handle, re-read the post and imagine it being said with a sideways grin.
((Bike Profile))
((Pics))
FIVE OUT OF FOUR PEOPLE DONUT UNDERSTAND FRACTIONS
((Bike Profile))
((Pics))
FIVE OUT OF FOUR PEOPLE DONUT UNDERSTAND FRACTIONS