95 kdx smoking problems?

If its jetting it will smoke more the higher the altitude .

Could be the crank seal that is leaking gearbox oil into the motor .

Have you checked what jetting you are running ?

I am not sure what stock its, but I just checked my notes and I was running 45 pilot, 155 main, and my needle clip was in the top groove. Seemed to run pretty good.

I ran 40:1 yamalube in it.

It was a '95 and that was for sea level in GA, whatever that is, 1000 maybe.

I have since went orange, but only because my greenie was stolen :pissed:

Good luck, it was a great bike and I sometimes miss it!
Only sometimes...........it was just so easy to kick, the KTM200 takes a little more umpgh!

Stock jetting on that 95 KDX is #48 pilot, 160 Main, and needle at 3rd clip if still needing to know. I actually just re-built one of these for my buddy and it is smoking like crazy everywhere, even after I went to a 45 pilot, 158 main, and needle in top clip. Funny thing is it's not fouling plugs, which leads me to wonder what it is.

We had the cases split for new bearings and seals, so I was thinking at first it was the right crank seal, but the plug thing is confusing. The owner cleaned the stock pipe (FMF unit sent out for repair) with deisel fuel to get the mice nest out of it. Perhaps there's some left in there causing this smokin', since it gets worse as it heats up.

Anyway, this thing was a little rich low-mid me thinks but it ran decent before we tore it apart with the following settings:

48 pilot, 158 main, needle in 3rd clip, Boyesen Rad Valve, FMF Knarly and shorty. I also got Yamalube at 40:1.

Now jet it correctly and you will be amazed at how much better it runs!
Cheers John

I have cured my smoking problems with adjustments to the needle. I think it's part throttle riding that loads the bike up and causes the spooge and smoke. I have the stock needle on the top clip, and I'm trying to source a leaner needle. Tons more power and no smoke to boot.

I've had similar experience with my '97 kdx200. I replated the cylinder this winter and put in a new wiseco piston. Took care of KIPS, repacked silencer, etc. etc. etc. Bike ran fairly well, but smoked and spooged. So I started leaning it out little by little. Original jetting was 160 main and 48 pilot with needle in middle groove. I'm now down to 150 main and 42 pilot and needle lowered to #2 position (i.e. clip in 2-nd groove from top). Plug looks considerably better, and almost no smoke and no spooge after it warms up, but I still don't like off-idle transition and the air screw does not have the impact like I think it ought to, so I'm going to try a 40 pilot tonight (I don't want to mess with slide cutaway just yet). My point is that you might have to lean it out A LOT before you get there - especially if you are in Houston where temps and humidity are very high, which would require even leaner jetting than my neck of the woods. Just take it one small step at a time.

BTW, in my experience ignition timing has profound effect on things when you start getting leaner. When I initially lowered the needle the bike ran like sh*t, so I went back to the middle groove. Later I discovered that previous owner retarded timing by 1 mark. I put it back to middle "stock" position, and now it runs well with needle lowered. I also tried advancing timing by 1 mark for supposedly better low end response, and I found that my bike didn't care for it too much, so now I'm back to stock timing.

For completeness: '97 kdx200. FMF Gnarly Rev pipe, PC304 silencer, Delta Vforce reeds. I've got airbox lid in place but with snorkel removed, and I'm in New England a little above sea level with temps in the 60's and 70's. Ignition advance is on the middle mark. Yamalube 40:1. 150 main, 42 pilot, #5 slide, 1174 needle in #2 position, A/S 1.5 turns out.