Help! Seeking new throttle/slide valve for 1999 KDX200

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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Help! Seeking new throttle/slide valve for 1999 KDX200

Post by NewEnglandKDX »

Hello All,

Longtime lurker but first time poster. I'v done as much homework as I can on my own and need some help.

I've owned an all original 1999 KDX200 for about five years now. It's never given me any trouble and it always starts and runs first or second kick. I just feed it a steady diet of fresh 32:1 and it works wonderfully. That was until the mice found it over the winter...I moved it from a garage to a newly constructed outdoor shed for my equipment and that was a mistake. The mice managed to find their way into the airbox, eat through the air filter and make a nest down against my carburetor. Long story short, the throttle valve/slide is so corroded and destroyed from mouse urine it's not salvageable. Hours of work with carb cleaner, rust remover and polishing with a Dremel were of no use. I need a new throttle valve/slide.

I usually just order any parts I need from Rocky Mountain ATV, but I soon learned that while almost any part is available for my KDX carb- the one thing not available is the throttle valve/slide. It's Kawasaki part #16025-1172 and no one in the US seems to have one. Discontinued I guess. Complicating matters is that I've read that the KDX used a unique throttle valve/slide and off the shelf PWK valves/slides won't be a match.

Two questions:

1) Does anyone know of a shop in the US that would carry a New Old Stock throttle slide for my KDX. Trying to avoid used.

2) Alternatively, does Keihin make an identical throttle valve/slide under a different part # that would exactly match my old valve. The bike runs and rides exactly how I like it, so my goal is to find identical replacement throttle valve/slide. I assume if they did though, they would be supplying it to Kawasaki and retailers like the other carb parts.

All thoughts and ideas appreciated. Thank you!
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by SS109 »

Jets-R-Us will have what you need. Matter of fact, since you're buying a new one, might as well change the slide profile at the same time. Many here have had great luck with a #7 slide over the stock #5.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by NewEnglandKDX »

SS109 wrote: 07:11 pm Jul 13 2022 Jets-R-Us will have what you need. Matter of fact, since you're buying a new one, might as well change the slide profile at the same time. Many here have had great luck with a #7 slide over the stock #5.
Thank you for your reply. Have you used Jets-R-US yourself for any orders and were you happy with the service? I was searching some past threads and there were some unhappy reviews floating about in regard to incorrect parts being delivered and other customer service issues. I have no opinion myself having never used them for anything, so it would be good to hear from others who have used them.

Their throttle valve chart mentions that KDX owners should not use their PWK slides, so I'm not sure which part to use. Which slide part # on their site would be identical to the stock KDX slide? The KDX has a custom PWK 35 is that correct?

It seems there are endless discussions on jetting, valve blocks gaskets and clip positions, but not much on the stock slide haha.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by John_S »

I’ve ordered about 5 times from jets r us and it was always painless with quick shipping. I’ve also called before and they were real helpful. I just looked and they actually changed the description at the bottom. It still says don’t use on kdx 35 but then under that it says “Kawasaki pwk35 can use either the 35 slides or the 35 air striker slides.
You mentioned wanting to keep it just like it was before and your stock slide is a #5

I’d order from them and also order a jet block gasket listed right above the slides while you’re at it.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by SS109 »

Yes, I've ordered through them many times without issue. They are the only place I know I will always get genuine Keihin parts. Call them about the slide. What their website says versus what they actually carry can be different.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by NewEnglandKDX »

Thank you for the input everyone.

I reached out to JetsRUs with an email asking for availability and a part number for the stock slide as well as a valve block gasket and jets.

In return I just got a link to a parts page where I guess you are supposed to figure it out yourself from the myriad of choices.

I’ll try calling tomorrow and see if that’s any more successful.

It’s kinda funny, they go out of their way on the website to explain you should contact them to confirm the correct part number before ordering, but when you do they don’t provide it and just want you to guess from a chart. Customer service in 2022 I guess…or I’m getting old and grumpy.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by SS109 »

Their customer service has always been great IME and I think I've ordered from them over a dozen times now. You probably got one of their regular people (not someone that actually understands these things or in to motorcycles) who just answer emails and such. Talking to someone who actually knows and is in to it will make a big difference.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by MoonStomper »

I recently replaced my slide with the ‘upgrade’ that I got from SUDCO. Here’s the link to that deal with details…
https://kdxrider.net/forums/viewtopic.php?f=86&t=25385

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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by SS109 »

MoonStomper wrote: 10:02 pm Jul 14 2022 I recently replaced my slide with the ‘upgrade’ that I got from SUDCO. Here’s the link to that deal with details…
https://kdxrider.net/forums/viewtopic.php?f=86&t=25385

Top shelf customer service.
Good info to pass along. I had forgotten about that thread.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by NewEnglandKDX »

UPDATE: I didn't have any luck trying to call JetsRUs today so I decided to email again and keep it simple and to the point. I said I just wanted the equivalent replacement for the original slide that came on a 1999 KDX200 (I also provided a Kawasaki part number). I also requested the part number for the original jets and jet blocks gasket on his site so I don't make an ordering mistake.

Mike replied by saying that many different throttle slides came on the 1999 KDX200 from the factory and there's no way to know what I need. He also didn't know about the jets and that I'd have to measure them and compare them. He also said he didn't know which valve block gasket I'd need and I should look for the picture that looks closest to mine on the website...

None of this sounds right...Are you guys sure this fellow knows anything about KDX's and these PWK carbs? Aren't the 1995-2005 KDX's pretty much all the same for the most part?

I'm going to try the Sudco place and see if that's any better. I'll let people know how it goes.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by SS109 »

Yeah, I don't know why he's saying that. However, they are a carb specialty shop and not necessarily an OEM (Kawi, Honda, etc.) specialist. Yes, all slides and jet block gaskets were the same through all 95+ KDX200's. Jetting might have changed a bit over those years, not sure, but it doesn't matter anyway. Just follow the info in the link above that MoonStomper provided. That covers the slide. The jet block gasket, just pull yours apart and look at the pics of the two different versions and order the correct one. As for jets, stock really doesn't work for 95% of KDX owners. Tell us what elevation are you at and we can get you in the general ball park on what sizes you should order along with needle recommendations.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by John_S »

For the slide order 018-241 and the jet block gasket is 1202-834-2000. It’s the one on the left on the website. You mentioned it ran great for 5 years. Click on the jets in the pwk35 parts break down and order a couple pilots and a couple mains that are above and below the jets that you currently have installed. For the main jets I just go in increments of 5. Like 155, 150, 145. I don’t mess with the 148, 152, 158.
Work with the needle you have and change clip positions to get it just right.

I think you’re overthinking it. Order them up and while you’re waiting on your priority mail envelope, search YouTube for PWK jet block and watch the video from Jason V. It won’t hurt having an extra gasket if yours is still good.

Sudco confirmed on that other post that the OEM PWK 35 takes the 35 air striker slides. When you look at the part numbers the 35 air striker and the PWK 33 take the same slides. The 018-241 is the #5, the same as your OEM slide.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by NewEnglandKDX »

SS109 wrote: 12:08 am Jul 16 2022 Yeah, I don't know why he's saying that. However, they are a carb specialty shop and not necessarily an OEM (Kawi, Honda, etc.) specialist. Yes, all slides and jet block gaskets were the same through all 95+ KDX200's. Jetting might have changed a bit over those years, not sure, but it doesn't matter anyway. Just follow the info in the link above that MoonStomper provided. That covers the slide. The jet block gasket, just pull yours apart and look at the pics of the two different versions and order the correct one. As for jets, stock really doesn't work for 95% of KDX owners. Tell us what elevation are you at and we can get you in the general ball park on what sizes you should order along with needle recommendations.
Thank you for confirming the carbs were unchanged.

As for making changes, my bike runs fine with the original 160 jet, etc and stock configuration. I just thought I'd put some fresh pieces in while I'm taking everything apart in case there's any wear from general use, cleaning and poking over the years. I know people modify their bikes a lot or are frequently trying to cure performance or fueling issues, but honestly it ran perfectly fine (at least until the mice found it).

If people are curious though I ride near sea level throughout the year as conditions allow in 45-82F weather using 32:1 synthetic fuel mix. Fall trail riding in New England is pretty common for me or a cooler summer day.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by NewEnglandKDX »

John_S wrote: 08:48 am Jul 16 2022 For the slide order 018-241 and the jet block gasket is 1202-834-2000. It’s the one on the left on the website. You mentioned it ran great for 5 years. Click on the jets in the pwk35 parts break down and order a couple pilots and a couple mains that are above and below the jets that you currently have installed. For the main jets I just go in increments of 5. Like 155, 150, 145. I don’t mess with the 148, 152, 158.
Work with the needle you have and change clip positions to get it just right.

I think you’re overthinking it. Order them up and while you’re waiting on your priority mail envelope, search YouTube for PWK jet block and watch the video from Jason V. It won’t hurt having an extra gasket if yours is still good.

Sudco confirmed on that other post that the OEM PWK 35 takes the 35 air striker slides. When you look at the part numbers the 35 air striker and the PWK 33 take the same slides. The 018-241 is the #5, the same as your OEM slide.
Thank you for the specifics- much appreciated! So PWK 35 air stryker in size #5 would match what's on the bike now it sounds like. Thank you for also clarifying the part # on the jet block gasket. The jet sizes I have now seem to be fine, just thought I'd toss a fresh set in to compensate for any wear and tear from years of use, cleaning, etc.

I'll let people know how it all comes together after I get the parts.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by KDXGarage »

I encourage all to try some different jets to make sure it is running as well as possible. Too much oil can cake up the subvalves with carbon. Better throttle response and more MPG come with finer tuning, if it is not already there.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by NewEnglandKDX »

Hi All,

Sorry it's taken so long for an update- between work and some health issues I just haven't had time to finish putting the bike back together until now.

I wanted to let everyone know the folks at Sudco were absolutely amazing in terms of customer service and it was a night and day experience compared to Jets-R-Us. I emailed Sudco about my needs and concerns and I had a detailed response within ten minutes. After speaking with them on the phone it was clear they knew the KDX carb very well and had the specific parts I needed. Overall, I found them professional and responsive.

They sent me the original Keihin slide along with new jets and a jet block gasket at a reasonable price. The parts shipped with tracking the same day I ordered and made it from CA to MA in just a couple of days. The slide was an identical match to the original along with the jets.

If you desire an exact factory replacement throttle slide/valve for a KDX the original Kawasaki part # was 16025-1172, but since Kawasaki no longer carries it is only available as Keihin part #018-241 now (as mentioned earlier in this thread by John S). Sudco confirmed the KDX used an Air Striker slide for a PWK35 and not a standard PWK slide from the factory.

They have a 614 page online catalog of vintage bike parts, so it seems like they're a great resource for all things carbureted.

Very glad I decided to replace the jet block gasket- it was a mess under there despite lots of cleaning and four hours of Chem Dip. Everything was sparkly clean elsewhere but a total mess where the jet block meets the carb body. One of the tiny fuel holes that feeds the engine side of the throttle bore was so small I needed a 14 gauge electric guitar string to clear it. In fact, it's so small you might never even know it's there.

I can see how people rebuild their carbs and replace their jets and find their bikes still run poorly or rich- a few things here and there that could be easily missed if you're not careful (especially that jet block gasket).

Thanks to everyone who chimed in on the forum- much appreciated.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by SS109 »

Chem Dip and jet block gaskets don't mix. Lots of people have ruined that gasket by soaking their carb in it and can't understand why their carb runs worse than before the "cleaning"

That said, glad to hear Sudco got it right and really took care of you.
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by MoonStomper »

Glad SUDCO hooked you up like they did me. Those folks ROCK!
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Re: Help! Seeking new throttle/slide valve for 1999 KDX200

Post by KDXGarage »

Kawasaki stated over 30 years ago that carb dipping ruined the gasket. It was in K Tech News I think.
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