118 replies to this topic

[hi_im_sean Get Help Now]

puvcustom said:

Plug Chop? Haven't heard of that one yet.

find a long safe straight
go WFO through all the gears, redline the highest gear you safely can and immediately close the throttle, pull in the clutch and hit and hold the kill switch all at once. come to a stop, pull the plug and take a reading. this will tell you if the main jet is correct, or too lean. im my experience, kdx's start loosing power before they blow up when you run them lean.

[samiam TT Bronze Member]

2004 KDX200
Air Box lid removed
FMF Woods Pipe and Silencer
V-Force Reed Cage
Main jet: 155
Pilot jet: 45
Air Screw: 1 1/2 turns out
Comments: The bike ran fairly well until I recently installed the V-Force Reed cage. Now it blubbers badly on the top end, and seems a bit rich on the bottom as well. I was researching new jets and found this thread. It looks like I will try a 38 or 40 pilot, and a 142-148 main jet. Folks have told me that the 38/142 combo will work well with my set up....

[cornishwrecker220 TT Newbie]

try running a 145 main with the needle clip 2nd notch from the top, pilot 40...what mix are you running??..40.1 is good for the above jetting but if i were you i would firstly try running the standard 32.1 & see if that cures your over rich fueling..if it works then there`s no need to pull the carb off & mess about with the jets..

[nicadrick TT Bronze Member]

Wibby,

What kind of range are you getting? What size tank?

[Wibby TT Bronze Member]

nicadrick said:

Wibby,

What kind of range are you getting? What size tank?

I think the "E" has a 3.4 gallon tank

I figured out the other day running mostly tight Southern Oregon single track, I'm getting around 18 mpg

I'm probably close to 320 - 330lbs in gear

[UI Vandal TT Newbie]

Year: 1996
Model: KDX 200
Where I ride: 4000'-9000' 55º F - 95º F, single track, atv roads, forest service roads
Engine modifications you have done: Stock exhaust, no airbox lid
Pilot jet: 42
Main jet: 152
Needle number/type and clip posistion: Third clip on stock needle
Air screw turns out: 1.75
Fuel: 91 or 93 octane (highest I can find) with 40:1 Amsoil Dominator
How's it working for you?: Bike pulls strong through the entire RPM range. It is jetted perfect for cool mornings at the lower altitudes, but can still chug all day long up high in the heat without fouling. Very little spooge up high and only smokes a bit on warm up or 95+ degrees at 9000+ feet. I would say it is a little on the rich side of things, but since it runs great, doesnt look like a Seafoam experiment, and never fouls why run leaner? Runs great and seems safe!

[Sthutch TT Newbie]

Year:  2001
Model:  KDX 200
Riding Altitude: 600'-900', 50F-90F, Central and Northern Michigan
Mods:  Top end rebuilt
           Boyesen 607 Reeds
           FMF Woods Gnarly
           FMF Turbine Core 2
Mix:  32-1 Super M, 91 octane fuel
Pilot:  38
Main   165
Needle:  1st Clip, R1174K 2AFKG (stock needle)
Airscrew:  1.75 turns out

Notes:
-Just finished jetting today.  0 to 3/4's throttle is great, but 3/4 to full is not quite there yet.  Lower end is crisp, smooth, and aggressive.  
-Plug color is on the dark side of brown, but not black after high speed chop tests.

Input welcome as I noted that nearly all jetting included reducing main jet size, not increasing it.  Any ideas as to why?

[Cuda7050 TT Newbie]

1997 KDX 220
200 Carb, Pro Circuit Pipe, open air box, boysen reeds
4,000-7,000 riding altitude, 73-83 degrees
40 Pilot
150 Main
1.5 out on the air screw
Needle Clip in second slot
Runs strong through rpm range, still spooges some. 42 pilot also worked well may have had more bottom end but lots of smoke and spooge.

[dackler TT Member]

04 KDX 200
FMF Woods pipe, FMF Turbinecore2 silencer, Boyesen RAD valve w/ 1pc CF reeds, Wiseco piston, airbox lid removed
Bel-Ray H1R @ 40:1
Elevation:500-1500ft
45 Pilot, 155 Main, 1.5-1.75 turns on the air screw, needle in 2nd clip (R1174K)
A bit of spooge but pulls very strong from down low up through mid-range. Plug looks good.

[kbob999 TT Member]

year: 2000
model: 200
conditions where you ride: 6000-9000' 60-80 deg.
engine modifications you have done: Boysen reeds (not sure type), drilled airbox lid w/ uni filter, FMF Gnarly Header, Answer S/A Muffler
pilot jet: 45
main jet: 148
Stock 1172N Needle and clip 2nd Position from top
air screw turns out: 0.5
40:1 H1-R oil, 93 pump gas

Hows it working for you?   New bike to me...only 3 hours.  Seems to need a smaller pilot, so I'm going to 42 next.  Main is good.  Will test a 1173 needle also. A little spooge, but not a lot. Power is weak at altitude, so I can't compare to you sea level guys.

[rkajr TT Newbie]

I have 1992 kawasaki kdx200 just rebuilt engine need to know what jetting to run it has 140 main, 42 pilot, stock needle 2nd position from top stock pipe still have stockair box lid   ride at 2000ft-5500ft

[cornishwrecker220 TT Newbie]

 cornishwrecker220, on 23 December 2010 - 01:31 PM, said:

United Kingdom..
rides at sea level on tight single rocky/muddy track trails & wooded climbs.
2004  kdx220.
fmf gnarly front, powercore2 silencer.
boysen rad valve, boysen reeds.
wiseco pro lite piston.
standard airbox with snorkle removed, twin air filter element.
40 pilot jet, 142 main jet, stock needle 2nd notch from the top.
air screw stock turns give or take.
40.1 mix.. rock oil lube with hardly any spooge from the tail pipe.
N.G.K irridium spark plug...burns fuel cleaner/better.
13t front 48t rear renthal sprockets..hd x-ring chain 520
Bike runs nice & crisp with a good throttle response..no bog just smooth power straight off the throttle..pulls very strong through all the gears & climbs anything.. can & will keep up with bikes worth 3x as much £ on the right trails.

... recently upgraded to a 35mm kdx 200 carb, kept the 220 needle/slide & main jet settings..  changed my gearing 13/45 & fitted a wossoner piston,..the best just got better!!

Edited by cornishwrecker220, 23 January 2012 - 12:39 PM.

[SS109 TT Platinum Member]

Southern AZ
2000-4500ft desert single track
65-110 degrees, 5-10% humidity

1990 KDX200
Timing set to middle mark
Wiseco piston w/Jet-Hot thermal barrier and anti-friction coatings
RB modified head and carb
Vforce III reed setup
FMF Fatty pipe w/stock silencer
BR8ES plug
Air box lid removed
No-Toil air filter
Chevron Premium 91
Maxima Castor 927
32:1 ratio

Main 152
PJ 40
Needle CEK - 2nd clip from bottom
Airscrew around 1.25

[webrx TT Newbie]

Man, reading this I am starting to think I may be running too lean, but bike will start and idle and revs slightly when running dry.  bike also spooges when runing.

1996 KDX200
5000-6500 feet
low humidity (high desert)
Usually ride in temps from 60 to 90
FMF pipe
Everything else I think is stock (just got it at the end of the year and only been able to run it around a little).

Came with the following jets
MJ: 145
PJ: 35

Just rebuilt carb, have a new petcock kit (float and fuel petcock leak by), float is out of adjustment (looks tweaked) so gonna try to set that all up to factory after I rebuild the petcock to see if that helps - may have to replace it.

The guy I got it off of didnt make the jet changes, the guy before him did - I am pretty sure from talking to him that he never did much of anything to the bike except fuel it.

Dave

[1MSIPPI TT Member]

year: 2002
model: 200
conditions where you ride: 1000' 45º-80º
engine mods: airbox open and added Gnarly and Turbine Core
main jet: 148
pilot jet: 42
needle number/type and clip posistion:  CEL/Mid
air screw turns out: 2 1/2 plus a hair
fuel: whatever's around with 40:1 whatchagot
how's it working for you?: Great!  Will be going down on the rear to a 45 soon, so I can acutally use first gear.

Edited by 1MSIPPI, 16 March 2013 - 02:25 PM.

[Zak129 TT Newbie]

1998
Kdx220r
Altitude 1000-2000' above sea level temps ranging from 20-60F so far.
Removed air box lid, uni filter with pj1, Vforce 3 reeds, fresh plated cylinder, Wiesco pro lite piston, FMF Gnarly woods, FMF Power core 2.
pilot jet 45
main jet 155
Needle is stock
air screw 1/2 turn out

A little smoke and spooge. Still breaking it in. Running 93 octane 32:1 with klotz. She is so much better than before. I did all of the mods at the same time from stock. Woah!

[sterlin44 TT Newbie]

1996 KDX 200
Riding in South Carolina at around 1000ft
40F-90F
Mods: snorkel removed,fmf torque pipe,Fmf q silencer
Main: 155
Pilot: 40
Air screw: about 2 turns
Needle: CEL 2nd slot from top
Mix: yamalube 2R at 32:1 with 93 octane
Runs pretty good. Plenty of torque down low. Pulls very hard from mid to top signs off a little early. Little smoke at all, not much splooge. Could be leaner on the main but I'm sticking with the 155 for extra reliability.

[Va countryboy TT Member]

2003 Kdx 220
Altitude 3000-5500
Temperature mid 60's currently
Low humidity for the most part
V force 3 reeds and snorkle removed
pilot jet 45
main jet 142
Needle is stock
air screw 1 1/2 turn out
mixing 40:1
overall very happy with this setup.Looking forward to getting my pipe and sending my head and carb out

Edited by Va countryboy, 27 April 2013 - 02:19 PM.

[KTM520EXC TT Bronze Member]

2000 Kdx 220
Stock 33mm PWK
PC Expansion Chamber / PC Silencer
Altitude: 2500-5000
Temperature mid 50's to mid 90's
Low humidity
Boyesen Reeds
Snorkle removed/Filter Lid modded with breather holes
Pilot jet 35
Needle at position 1 (top clip) (Stock)
Main jet 135
Air Screw 2.25 turns out
Mixing Ratio: 32:1