Hello!
I have a 2003 KDX 200. The bike is running very rich. It will not rev out. All the top end power is just not there. I am running a basically brand new stock expansion chamber and silencer after switching out the old FMF setup. I rebuilt the carburetor with all stock jets and cleaned it so its spotless. I even have the c-clip needle valve adjustment on the leanest setting and its still too rich, it wont rev out in high rpm's. So the carburetor is not the problem. My air filter is good. Im running 32:1. The gear oil when I changed it seemed kind of milky like a grayish color but it still felt like oil. Does anyone know what the problem is? A bad KIPS, needing a new top end, crank seal? I just bought this bike and want to get her running right! Any help is very much appreciated!
Did you "dip" the carb in carb cleaner? If yes, you probably damaged the jet block gasket which would cause a rich mixture due to jet block leakage. Do a search on this site for JET BLOCK GASKET. There's lots of threads on that subject.
What about the KIPS assembly? There is/was an error in the factory service manual on KIPS assembly. If assembled wrong, this will cause poor performance too.
Do you have a Service Manual? If no, you should get one. It's the most important tool needed to care for your KDX. See this site's home page for information on getting one.
pumpguy wrote:Did you "dip" the carb in carb cleaner? If yes, you probably damaged the jet block gasket which would cause a rich mixture due to jet block leakage. Do a search on this site for JET BLOCK GASKET. There's lots of threads on that subject.
What about the KIPS assembly? There is/was an error in the factory service manual on KIPS assembly. If assembled wrong, this will cause poor performance too.
Do you have a Service Manual? If no, you should get one. It's the most important tool needed to care for your KDX. See this site's home page for information on getting one.
I was thinking the same thing. I did not dip my carb in carb cleaner. It is possible the jet block gasket can be bad though. I am going to order one, I can only seem to find them on eBay from a seller in the Netherlands. Do you know anywhere else I can get one? I need to watch some videos and do some reading on the KIPS assembly. I take it as it is Kawasaki's version of the power valve. The service manual is on my list of things I need to get. Thank you.
I just ordered 2 jet block gaskets from Jets-R-Us and they were at my door 3 days later. I have used them many times with no issues, but I do hear if you are outside the US it may be problematic.
KIPS would be where I would look next if it is running good on the bottom but not above 6k rpm. You said your oil was gray and milky which indicates a bad water pump mechanical seal allowing coolant into your oil (or your bike spent time as a submarine).
bufftester wrote:I just ordered 2 jet block gaskets from Jets-R-Us and they were at my door 3 days later. I have used them many times with no issues, but I do hear if you are outside the US it may be problematic.
KIPS would be where I would look next if it is running good on the bottom but not above 6k rpm. You said your oil was gray and milky which indicates a bad water pump mechanical seal allowing coolant into your oil (or your bike spent time as a submarine).
bufftester wrote:I just ordered 2 jet block gaskets from Jets-R-Us and they were at my door 3 days later. I have used them many times with no issues, but I do hear if you are outside the US it may be problematic.
KIPS would be where I would look next if it is running good on the bottom but not above 6k rpm. You said your oil was gray and milky which indicates a bad water pump mechanical seal allowing coolant into your oil (or your bike spent time as a submarine).
From bufftester... "(or your bike spent time as a submarine)"
I posted a pic of a lime green submarine.
What he is meaning is that if someone before you drove it through deep water, it could have water inside the transmission / clutch area. Not likely what happened here, as I think he was just kidding, as I was toward him with the picture.
Get a T-20 security Torx and check / replace the jet block gasket. Beyond that, compression test, reeds, pressure test, vacuum test. You might also want to take the pipe off and look at the side of the piston for its condition. It is not as good as taking it all apart, but it could be enough to see a big problem.
Jason wrote:From bufftester... "(or your bike spent time as a submarine)"
I posted a pic of a lime green submarine.
What he is meaning is that if someone before you drove it through deep water, it could have water inside the transmission / clutch area. Not likely what happened here, as I think he was just kidding, as I was toward him with the picture.
Get a T-20 security Torx and check / replace the jet block gasket. Beyond that, compression test, reeds, pressure test, vacuum test. You might also want to take the pipe off and look at the side of the piston for its condition. It is not as good as taking it all apart, but it could be enough to see a big problem.
I have already stripped the carburetor down completely down to nothing. I have already taken off the jet block gasket and it looked fine. I washed it with some dawn dish soap and warm water and popped it back in just for now. I know I need to order a new one, you should never reuse gaskets. Do you know where the reeds are located in the bike? And yes thats a good idea, I should pop the exhaust back off again and check to see if there is anything that stands out to be a problem. Good idea man! Thanks.
A couple of things one can see from looking into the cylinder from the exhaust port is carbon build up on top of the piston and oil blow by on the side of the piston.
