1987 kdx 200 new carb boot or try repair?

[tncsparky]

So it looks like my carb boot has cracks in it. I haven't pulled it out yet to check if they go all the way through.
I am not having much luck tracking down a new boot. I did read about a repair using a sikaflex product to fill the cracks but they didn't give the tube type.
How does the repair hold up?
I wonder if another boot matches up from a Kx
What are my options?

[sarrant]

Several folks here have had good luck using plasti-dip. I've never used it for that purpose, but having dealt with it for other things, I can see how it would work well.

[KDXGarage]

There was a seller on eBay making them for various older models.

1986 - 1987 KDX200 is for the Mikuni, and 1988 is for Keihin.

[Goofaroo]

I used the aerosol plast-dip about 18 months ago and it has worn like iron. As far as I am concerned it seems like a very viable repair and I plan to use it as needed on future projects.

Wile you are at it, take a close look at your airbox boot. On my 87 model, it was cracked as well.

[tncsparky]

What did you do for prep before applying the plasti dip?
Did you open the cracks to get it inside and then later spray the outside?

Thanks guys

[Goofaroo]

I just scuffed the outside with some 60 grit and a wire brush. Then I taped off the openings and sprayed them with 4 or 5 coats of Plasti-Dip.

[tncsparky]

Thanks. I will give it a shot

[87KDXfan]

I realize how old this thread is however I wonder if blasting it with FlexSeal would work?

[KDXGarage]

Check for gasoline tolerance.

[JimmyB]

I realize how old this thread is however I wonder if blasting it with FlexSeal would work?

Try this, Seal All. Have used it for decades on fuel tanks/oil tanks at work and very gasoline/solvent resistant, scuff up the surface with sandpaper, clean the surface with alcohol/brake clean etc. and spread a couple thin layers with a paint brush.

https://www.autozone.com/sealants-glues ... 1b60be6627

[87KDXfan]

I'll have to give that a try, thanks

[87KDXfan]

I dug into the 87 a few minutes ago. Not good but fortunately I caught it in the nick of time. Carb holder is much more severely cracked than I expected. The Mikuni is leaking internally (overfilling), and correct me if I'm wrong, but I always thought reeds were supposed to seal flat against the reed cage and not open slightly (I'd guess .003" or so) out at the ends. So now I'm trying to decide if I should replace the worn parts and fix the carb OR do the 1988 refit with das boots, carb and throttle cable if needed...

[KDXGarage]

Can the reeds be flipped over?

[JimmyB]

Looks like these guys sell some aftermarket replacements.

https://www.ebay.com/itm/114157762261?m ... 1b60be6627

[KDXGarage]

Yes, that's the seller I remember. Thanks. The air box to carb boot is different, too. They have the 86-87 and the 88 carb to engine boots as well as the 86-87 and the 88 airbox to carb boots.

[mechashiva76]

hello, new here and just wanted to add my 2 cents... and maybe get suggestions. I purchased the intake manifold and the airbox boot for my 1986 kdx200 about a year ago from the seller mentioned above. right off the bat I noticed there were some fitting issues. the boot doesn't fit flush on the carburetor and the extra thickness on the manifold intake base was causing my carburetor (unbeknownst to me until last night) to rub against the metal boot mount on the airbox. causing a wear divot a couple millimeters deep on the ring and my carburetor.

I contacted them about the fitting issues. they suggested taking the manifold intake base to a belt sander and removing 1mm of thickness. I haven't tried this yet, but the stock base is easily 4mm thinner than the after market one. Not to mentioned, the aftermarket one requires an additional gasket which is another 1mm thickness.

for now, I'm going to revert back to the stock intake manifold. it has some small cracks in it, but they don't go all the way through. My airbox boot has cracks that definitely go all the way through. I'm hoping the aftermarket airbox boot will fit better[album][/album] with the stock manifold intake. otherwise I'll be patching the stock airbox boot based on a youtube video I saw that used black silicon sealant and super glue.

I'm very disappointed considering the intake manifold and airbox boot were close to $200 for the both of them.

[KDXGarage]

Thank you for the report. Sorry to hear they didn't work out great.