Carb overflows when bike is leaned at 45 degrees

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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MoonStomper
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Carb overflows when bike is leaned at 45 degrees

Post by MoonStomper »

This happens with petcock open, bike off or while running and it just spews!
Would your first guess be to inspect and/or replace Replace the needle valve / complete seat assembly?
Probably been two years since I replaced it, riding year round with no ethanol exposure.
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Re: Carb overflows when bike is leaned at 45 degrees

Post by KDXGarage »

Do you drain the bowl after riding?

I would take it apart and clean it.
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Re: Carb overflows when bike is leaned at 45 degrees

Post by bufftester »

Make sure your float is moving freely
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Re: Carb overflows when bike is leaned at 45 degrees

Post by billie_morini »

1) clean float bowl
2) clean & inspect rubber tip on float valve needle (replace if hardened)
3) measure (& reset float level; typically 2 mm lower than shop book says)
4) verify floats will float
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Re: Carb overflows when bike is leaned at 45 degrees

Post by MoonStomper »

Ten-four! I’ll dig into this tomorrow.
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Re: Carb overflows when bike is leaned at 45 degrees

Post by SS109 »

billie_morini wrote: 08:45 pm Apr 27 2023 1) clean float bowl
2) clean & inspect rubber tip on float valve needle (replace if hardened)
3) measure (& reset float level; typically 2 mm lower than shop book says)
4) verify floats will float
Yep, all great things to check while you're in there. :supz:

I do believe if it only does it when leaned, it's a float issue. Either binding, losing buoyancy, it's set too high, or any combination of the three. Oh, also check to make sure your carb is level in the chassis.
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Re: Carb overflows when bike is leaned at 45 degrees

Post by MoonStomper »

You guys are awesome, thanks!
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Re: Carb overflows when bike is leaned at 45 degrees

Post by smelonas »

Had the same problem with mine. Caused fuel consumption to skyrocket. Found out that the float needle was sticking in the bore because the float needle had worn out and was very loose in the inlet tube bore. New one fit nice and snug and fixed the problem. Also replaced float just because. If you have a few hundred hours on the carb, I recommend just replacing the whole thing. By the time you buy the parts to refresh the original, you could basically buy a new one.
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TX300i in my sights :tonqe:
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Re: Carb overflows when bike is leaned at 45 degrees

Post by MoonStomper »

Pulled out the carb and checked float measurement - out of spec - 3 mm lowering adjustment seemed to do the trick. Float looked good and clean as did the inside of the carb. Float needle still looked fresh and passed the blow test. Took her out for a rip and found no drip. Good to go!

Thanks again ya’ll!
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Let the good times ROLL!!!!!!!!!!!!!!!!
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Re: Carb overflows when bike is leaned at 45 degrees

Post by SS109 »

Awesome! :supz:
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Re: Carb overflows when bike is leaned at 45 degrees

Post by KDXGarage »

Sweet. Congratulations.
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Re: Carb overflows when bike is leaned at 45 degrees

Post by billie_morini »

Hooray for Moonstomper!
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