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Hey guys greetings from Greece!
I have purchased a new PWK 35mm carb for my ‘89 KDX200-G to replace a PE Keihin carb that I found on the bike. The PWK is obviously bigger and won’t fit into the air boot and trying to put extensions is impossible due to lack of space!
Any help would be really appreciated!
Many thanks in advance!

That's a tough one, I don't know how you are gonna get that to fit.

It also won’t fit to the engine side as well, into the boot in front of the reed valves....

Oh gosh I might put back the old carb for today. I desperately need to go for a ride , such a wonderful weather here guys!

Your intake boot is clearly torn so I wouldn’t go riding off into the countryside just yet. That may explain your carb problems.

What is it you’re trying to do? Is the carb that came with the bike the original carb from the factory? We didn’t get this model in the US but it appears to have an oil injection system. Are you planning to retain that?
What are you hoping to accomplish with this new carb that clearly doesn’t fit? What is wrong with the carb that was on it? How is the oil injection operated? From a vacuum port and the throttle cable linkage?

You might be better served to repair the original carb and intake boot and then go ride off into the hills.

It would probably cost you a few bucks but you need to have a local machine shop make you an adapter ring for the air box boot. Depending how you make it, epoxy the ring to either the ID or OD of the carb and the other end will fit the ID of the air box boot. This would add maybe 3/8 to 1/2” to the overall length of the assembly . For the reed cage side of the carb they will have to machine the spigot OD of the carburetor to fit. This is ok as long as the wall thickness doesn’t get to thin.

Maybe look into just rebuilding your carb.

Goofaroo wrote: 09:13 am Apr 09 2021 Your intake boot is clearly torn so I wouldn’t go riding off into the countryside just yet. That may explain your carb problems.

What is it you’re trying to do? Is the carb that came with the bike the original carb from the factory? We didn’t get this model in the US but it appears to have an oil injection system. Are you planning to retain that?
What are you hoping to accomplish with this new carb that clearly doesn’t fit? What is wrong with the carb that was on it? How is the oil injection operated? From a vacuum port and the throttle cable linkage?

You might be better served to repair the original carb and intake boot and then go ride off into the hills.

Thanks for the reply! The previous owner had an old Keihin PE carb on the bike. KDX200 service manual states that it should be used a Keihin PWK 35mm carb. The manual is for H series of course, my bike is a KDX200-G ‘89, can’t find the specific manual but I assumed it applies for my bike as well.
I’m not trying to do something in particular other than renovate the bike and have fun as I used to do when I was younger (I’m 39 now and I used to own a KDX at 18).
After a lot of search and reading the manual I decided to purchase a new carb along with the other parts I buy to improve the bike.
In regards to the oil injection it seemed disabled to me so I didn’t touch it.
Nothing wrong with the old carb, just a 32 year old carb and I thought to buy a new one for the next 30 years (optimistic :) that’s all.

kick wrote: 10:01 am Apr 09 2021 It would probably cost you a few bucks but you need to have a local machine shop make you an adapter ring for the air box boot. Depending how you make it, epoxy the ring to either the ID or OD of the carb and the other end will fit the ID of the air box boot. This would add maybe 3/8 to 1/2” to the overall length of the assembly . For the reed cage side of the carb they will have to machine the spigot OD of the carburetor to fit. This is ok as long as the wall thickness doesn’t get to thin.

Maybe look into just rebuilding your carb.

Hey man thanks for the reply! I’ve been to a machine shop and I asked them to do exactly this , it will cost 40euros and will be ready on Monday morning.

I am aware of the extra space it will need and to be honest I already freak out cause it might not be possible to fit and waste the money.

I was wondering if my G model has nothing to do with the E models and I follow a dead end here..

I own an H so I can’t comment on what carb should be on there. I would think your air box boot should have enough flex for that adapter.

The H series bikes are completely different. Almost everything in that service manual will not apply to your bike. Might as well use a manual from a 2007 KX450.

I still don’t understand the problem. Was your bike running well before you took the carb off? Just because the carb is old doesn’t mean it isn’t serviceable. It could run for another 30 years or more with a bit of maintenance.

Your immediate problem is the tear in the intake boot. Did that happen when you removed the carb? It will have to be repaired or ideally replaced.

If you try to stretch that 30 year old airbox boot over the new carb you could very well end up tearing it and it may not be easy to find. If for some reason you are compelled to do this you need to at least warm it up with a heat gun to give it a fighting chance.

I hope I don’t sound harsh but unless you’re not telling us the whole story you seem to be creating problems where none existed.

kick wrote: 11:01 am Apr 09 2021 I own an H so I can’t comment on what carb should be on there. I would think your air box boot should have enough flex for that adapter.

Unfortunately doesn’t fit it’s about 0.5cm smaller than the pwk35 carb even if I warm it and stretch it, it might crack.

Slick_Nick wrote: 12:18 pm Apr 09 2021 The H series bikes are completely different. Almost everything in that service manual will not apply to your bike. Might as well use a manual from a 2007 KX450.

EDIT: Please do not post links to illegally copied manuals on the kdxrider.net site. The site does not want to be involved in any copyright issues.

Thank you.

Goofaroo wrote: 01:04 pm Apr 09 2021 I still don’t understand the problem. Was your bike running well before you took the carb off? Just because the carb is old doesn’t mean it isn’t serviceable. It could run for another 30 years or more with a bit of maintenance.

Your immediate problem is the tear in the intake boot. Did that happen when you removed the carb? It will have to be repaired or ideally replaced.

If you try to stretch that 30 year old airbox boot over the new carb you could very well end up tearing it and it may not be easy to find. If for some reason you are compelled to do this you need to at least warm it up with a heat gun to give it a fighting chance.

I hope I don’t sound harsh but unless you’re not telling us the whole story you seem to be creating problems where none existed.

Yes the bike was running perfect, only some oil burning from a crankshaft seal which I replaced it. The carb was fine I just thought I could replace it to give some more strength.

I have already ordered a new intake boot. I will replace it. No it was like that when I bought the bike. I am also replacing the reeds.

No I won’t stretch the air boot, I took it to a machine shop and they will build a small extension instead.

You don’t sound harsh all good! Your comments help me to think of more ideas and many thanks for that man.

Just makes me think whether I should look for an H model to get the most out of KDX200, I notice that for these models you can practically find any part you wish, where for the G models things are pretty tough

Can you get a model "E" carb to airbox boot? It looks like maybe you could cut and modify the box, then buy whatever plate mounts it to the box

KDXGarage wrote: 06:56 pm Apr 09 2021 Can you get a model "E" carb to airbox boot? It looks like maybe you could cut and modify the box, then buy whatever plate mounts it to the box

Thank you KDXgarage, that’s a good idea! I’ll see what I get on Monday from the machine shop, if I’m lucky it will work like this (with the extensions for both boots) if not I’ll follow your suggestion and look for a used Airbox boot from an E model

Hmm, interesting. I would be looking for a (don't know if there is a difference to Greek spec) US spec manifold and air box boot from an '89-'94 KDX200. The PWK should then mount right up.

I would definitely not cut or modify any of the parts needed to mount your current “functional” carburetor.
That way if this experiment of switching to a different carb doesn’t work out you can switch back to the carb that seems to work perfectly.

I assume you have an SR model going by the PE carb and the oil pump showing in one of your pics.
Are you running premix? If so, the afforementioned "E" model intake and airbox boots might work. If you aren't premixing then you will need to make sure you don't lose the oil feed that is in the intake boot.

DIO1981 wrote: 01:56 pm Apr 09 2021

Slick_Nick wrote: 12:18 pm Apr 09 2021 The H series bikes are completely different. Almost everything in that service manual will not apply to your bike. Might as well use a manual from a 2007 KX450.

EDIT: Please do not post links to illegally copied manuals on the kdxrider.net site. The site does not want to be involved in any copyright issues.

Thank you.

My dearest apologies!!!

SS109 wrote: 01:13 pm Apr 10 2021 Hmm, interesting. I would be looking for a (don't know if there is a difference to Greek spec) US spec manifold and air box boot from an '89-'94 KDX200. The PWK should then mount right up.

This is a model that was never imported in the US, every little thing seems to be different to the E model, wish I could find an E or an H model