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I have seen that this carb does work, but does it need to be modified to work with the KDX? My mechanic is having a heck of a time getting it to fit.

The size is different. One of the boots is about a millimeter different, but the other is several. When Kawasaki used Keihin in 1988, they had different boots for the carb to engine and airbox to carb.

You might need to shop for a 1988 boot. hotfootmoto on eBay sells boots.

What about for the throttle cable and top of the carb. The 90deg cap will not fit on the new carb?

Keihin cable for a Keihin carb, Mikuni cable for the Mikuni.

The 1988 cable is not the same as the 1986 - 1987.