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Got brackets and mounts tacked up ready for someone that can weld , lectron pro carb sorted and fits like a glove, only issue left is the clash with the tank and cooling outlet off the top of engine which I don’t really want to start warming the tank and remoulding unless I have no other option, I may go down the route of modding or manufacture an alternative top section

Looking good. Next thing you know, you'll be on the first rip.

If you do end up heating the tank, go easy. It doesn't take much.

Finally got 220 engine back, had a slight port for top end and a light skim of head and a vapour blaster, should have it all together in the next week and will upload pics along way

on my 220 hybrid in a 2001 KX125 frame I had to also heat and remould the tank. As Ridea200 said, take it slow with the heat gun. You don't have to have a ton of clearance, I got about 3/8 of an inch and have not had any issues with it in the last 10 years. One thing I did have issues with is the fuel line. Where yours looks like it's a little kinked right where it comes out of the petcock, mine was like that and the hose was riding on the bolt for the reed cage. Took 10 years, but this last summer turned on the gas one day and it just started dumping fuel where the bolt head had rubbed a hole in the fuel line. My fix was to go with a thicker fuel line, but just something to be aware of.

It is looking good. Consider a sleeve around the fuel hose. Let the sleeve take the abrasion and just replace the sleeve sometimes.

Thanks guys will look at the fuel hose once engine finished and looking to see if I can shave a bit off the top coolant connection along with warming up the tank to sort that issue .
Will keep you all updated

Curious What work did you have done on the 1990 200E engine?

The engine

Engines in and been running although when warmed up seem to have a hairline crack on inner clutch case that has a minor oil leak , not a major issue as I’ve picked one up and cleaned up on home made vapour blaster and just waiting on water pump seal

Next issue is the frame and water pump protection , anyone any idea , I was thinking a kdx sump gaurd that wraps around to protect water pump and modding to fit the kx frame

All finished ready for run out although just miss placed frame cover for right side which will turn up and hopefully give it a run out next week

1fletch wrote: 10:01 am Apr 26 2025 All finished ready for run out although just miss placed frame cover for right side which will turn up and hopefully give it a run out next week

BEAUTIFUL!

DANG! Sharp looking bike there. Congratulations on your hard work paying off.

Thanks guys took some time to get this one complete and learnt a lot along the way
Got the 1990 kdx 200 that I originally purchased to start on next although engine has been fully rebuilt as it was going in this although I have to pick up a rear hub / wheel as it has a crack in the one I have
Will start a new thread on that build and wanted to thank everyone for the input along the way for this build