1990 KDX200SR

Discussion specific to KDX models not sold in the USA
Goatfish
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Re: 1990 KDX200SR

Post by Goatfish »

What a neat rebuild!
I am curious to know what the oil tank looks like and where it goes.
hi-def
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Re: 1990 KDX200SR

Post by hi-def »

I don't have pics at hand of the whole tank but you can see it here, it sits on the right hand side of the frame underneath the fuel tank.
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And here is the oil pump just below the intake with a hose running to the inlet manifold.

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Re: 1990 KDX200SR

Post by KDXGarage »

What is the knob?

Thanks for the pics.
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hi-def
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Re: 1990 KDX200SR

Post by hi-def »

In the bottom pic? That is the idle adjustment on the PE28 carby, quite convenient but not necessary.
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Re: 1990 KDX200SR

Post by KDXGarage »

OK, yet another tidbit we didn't see in the USA.
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1fletch
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Re: 1990 KDX200SR

Post by 1fletch »

Great post with plenty of information , I have also acquired the sr model with the upside down forks , do you have any information as to what they are , I am looking at rebuilding mine
hi-def
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Re: 1990 KDX200SR

Post by hi-def »

1fletch wrote: 02:01 pm Nov 02 2021 Great post with plenty of information , I have also acquired the sr model with the upside down forks , do you have any information as to what they are , I am looking at rebuilding mine
Cheers! All the non-SR specific info I got from this site including about the forks, I have actually just received some new Racetech springs today to install some time in future.

The 200SR forks are the same as the 93/94 model KDX200's so the instructions for them can be used.
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Re: 1990 KDX200SR

Post by KDXGarage »

1fletch, welcome to kdxrider.net. Start a new thread and a few of us can help you out some. I have had some apart and rebuilt them before more than once.
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hi-def
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Re: 1990 KDX200SR

Post by hi-def »

I'm a bit behind on progress so here's an update.
After the engine went back in it was looking good, break in went well and it pulls hard, lots of fun.

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Then I decided to change the silencer as I had an unused set of Toomeys from my RD400, sounds good now

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Re: 1990 KDX200SR

Post by hi-def »

Then I decided I wanted to swap to the bigger (standard) carb on the E model from the 28mm SR one, so started sourcing parts.

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hi-def
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Re: 1990 KDX200SR

Post by hi-def »

The SR has an oil injection port on its inlet rubber and the replacement one does not.

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So I'll drill out an unused boss on the PWK35

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Then press in a brass fitting from a spare carb with some loctite

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hi-def
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Re: 1990 KDX200SR

Post by hi-def »

Next up was the valve, I filed a spare down using a drill and can now insert it inline before the carb.

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Here it is installed

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The last piece of the puzzle was the oil pump itself, knowing I'd need it to deliver more oil for the larger carb I took a chance and bought a pump from a KDX250SR, good news, after opening it up I found it had a 4mm piston compared to the 3mm one off my bike.

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After swapping the drive gear (which had a different offset) it went straight back in

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Re: 1990 KDX200SR

Post by hi-def »

A couple extras were added after
Some reeds

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and a new float bowl for a laugh, seems to be ok so far

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Slick_Nick
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Re: 1990 KDX200SR

Post by Slick_Nick »

Hey that's some great work! I like that clear float bowl!
'00 KDX 220R
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Re: 1990 KDX200SR

Post by KDXGarage »

Heck yeah! Looks nice!
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Slick_Nick
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Re: 1990 KDX200SR

Post by Slick_Nick »

i found that float bowl on ebay, doesn't look like it has a provision for any sort of overflow tube, or a removable bowl plug. If your float ever sticks open, it'll likely fill your crankcase with fuel before it comes out of the breather hoses on the carb.
'00 KDX 220R
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