1990 KDX200SR

[Goatfish]

What a neat rebuild!
I am curious to know what the oil tank looks like and where it goes.

[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.


And here is the oil pump just below the intake with a hose running to the inlet manifold.

[KDXGarage]

What is the knob?

Thanks for the pics.

[hi-def]

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

[KDXGarage]

OK, yet another tidbit we didn't see in the USA.

[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]

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.

[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.

[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.



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

[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.

[hi-def]

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



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







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

[hi-def]

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



Here it is installed



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.



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

[hi-def]

A couple extras were added after
Some reeds





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

[Slick_Nick]

Hey that's some great work! I like that clear float bowl!

[KDXGarage]

Heck yeah! Looks nice!

[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.

[hi-def]

Yeah it's not the best design, unfortunately my original metal bowl will do the same due to a previous owners handiwork :(

[PeterW]

EDIT: (what you typed was edited out)

Please leave kxrider.net out of the copyrighted manual discussion as I mentioned earlier in the thread.