Tico

Member
Feb 6, 2004
49
0
Hi there!

I just bought a KDX200-G4 (KDX200SR), it is supposed to be a 1996, but it looks more like a 1992 to me. I am not really concerned about the actual year of factory, but I would really like to get accurate info on this model, which I have not been able to find anywhere on the Internet.

Canadian Dave suggested me to enter this forum and find JAGUAR for information ... So JAGUAR, please help!

I would really appreciate if there's any of you guys who can enlight me with info on this model.

Thanks in advance!
 

canyncarvr

~SPONSOR~
Oct 14, 1999
4,005
0
Doesn't the VIN# sort that out?

You should be able to do a search for one of jag's posts and PM him..

Well, maybe you have to be a vaunted subscriber to do that.....

Or, I could do it for you, send him a PM with a link to this thread and tell him, 'You're being paged.'

....and so I did.

Cheers!
 

Tico

Member
Feb 6, 2004
49
0
Thanks for your response Canyncarvr!

The thing with the VIN is that it was probably removed or has it somewhere else (not in the left side of the steering).

On the left of the steering it says: MADEINJAPANKH1
There's also a little kind of sticker with japanese characters, the only readable text is: DX200G / II-157.

Though, I have the chasis and engine numbers, as follow:
#Chasis (This is supossed to be the VIN as well, accordng to the papers): DX200G-027909
#Engine: DX200GE-018124

Maybe someone can help me now there's a bit more info.
 

canyncarvr

~SPONSOR~
Oct 14, 1999
4,005
0
If it's an 'H' model, it's not a '92.

The 'SR' part has caused problems with us US guys in the way of identification of 'stuff' before, though..........

Jag's not always around. If he's not epoxying his transfer ports or grinding on some engine part to see what happens he's out riding somewheres. He may not get back to you poste haste.

Good luck!!
 

canyncarvr

~SPONSOR~
Oct 14, 1999
4,005
0
re: this can be a problem on a hot two stroke.

Yep. Lean throttle roll is hell on t-smokes! Best to not do it, which is to say, AVOID doing it.

**edit**
oops. Wrong date.
 
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jaguar

~SPONSOR~
Jul 29, 2000
1,464
79
South America
hi all
man, I got it running again the same day. Sandpaper and a good pocket knife does wonders! I guess we're never too old to learn something new, like don't keep it on-the-pipe at low throttle opening!
Anyway the SR has a smaller carb and air filter, engine oil pump and reservoir for the oil, speedo, turn signals, and higher gearing by sprockets. Mine also has a 19" rear tire.
Take a look at my page on SR modifications and then get back to me with any questions.
oops I don't know how to get my signature to display! help Canyon!
see http://www.geocities.com/a57ngel/moto/SR.html
Tico, are you still in your home country of Costa Rica? (Thats what the locals are called there.)
If you are then whereabouts? I used to ride in the mountains of Santa Ana, just west of San Jose. Man, I miss that scenery and fresh mountain air!
 
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Tico

Member
Feb 6, 2004
49
0
Thanks a lot guys! Now I know it is a 1992 for sure!

JPM200, that surely helps, thanks buddy!

JAG, Nice page you got! Really enlightening. Good to hear you got your bike running the same day. Yes, I am in Costa Rica. Actually I live in Heredia and work in Santa Ana, I've got a nice view of the mountains from my office.

I just got this bike a couple weeks ago, thinking of using it mainly to go to work during the summer days, which are just awesome here. It needs a little work, wich I already started. I am supposed to meet today a guy whe has a MIG so we can make the pipe mods. I also have an extra silencer which I opened in order to modify, let me give it a try an I'll tell how it went. Also the powervalve seems to be stuck, I'll robably have to check the cilinder and work on that power valve -it leaks oil-. The bike seems to be too rich (it smokes a bit, specially when it's cool), if I am able to get the pipe worked this will probably help with the carbs richness.

At this moment whe (my wife Wendy and me -Mauricio-) are getting ready to take our kids (Alex -5- and Andres -2-) to swim a bit. After this I am planning to go see the guy with the MIG and hopefully get the modified pipe and silencer. I'll keep you guys updated. See you soon!

Thanks a lot and greetings from Costa Rica! Are yu guys mstly Canadian or from the US?
 
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jaguar

~SPONSOR~
Jul 29, 2000
1,464
79
South America
I had cut my pipe open to start to gut out the insulation but gave up on it when I saw how extensively it is double-walled. The insulation starts at the header and goes farther than halfway of the pipe! Too much for me. For one, it would be near impossible to get it out of the header and then even if you did it leaves the header section too wide. Someone else already did it and said it left the bike with less power than it had before. Save your pennies and buy an aftermarket pipe or make your own.
So have you ridden up the mountain just south of Santa Ana? That's where I used to ride. If you go over to the other side of the mountain then there are two long trails leading to the next small town. Going there and back is a great ride and takes a couple hours. Just don't try it when the ground is wet because some of the trail sections are hard packed slick clay that is near impossible to get through because there are bike swallowing ruts. very challenging
 

Tico

Member
Feb 6, 2004
49
0
Hi Jag!

Well no luck yet with the pipe mod, I was able to go to my friends shop yesterday, I'll have to wait until next week. I've been also thinking of getting an aftermarket pipe and silencer instead. So far, I know a guy who has in stock ProCircuit pipe an silencer and there's another place where I can also buy an Answer silencer (I think I like the Answer silencer above the Procircuit). So far, the ProCircuit pipe seems t be only available here. I'll probably end buying the aftermrket parts. YEsterday I gor a couple Pirelli MT21, which I'll store until I can make the other mods and have the bike as I want.

Yes I've been south Santa Ana, nice trip! I did that some years ago wit a friend of mine. In that moment I was riding a Suzuki TS125X (water cooled); which I still keep and hope to fix for my wife. I really enjoyed the ride. I hope I'll find some other people who like mountain riding so I can go out the mountains again (lately it has becomed a bit dangerous out there like for going alone).

Pura Vida!
 

jaguar

~SPONSOR~
Jul 29, 2000
1,464
79
South America
When I was there 3 years ago there was always a group of ticos riding those trails every weekend. But they approach the mountain from the east and enter by a really steep jeep road, so you won't encounter them by waiting around at the Santa Ana entrance to the mountain. When I was there I just heard that the steep trail leading up to the big cross was dangerous. I used to always ride alone and never had any problems although some people in the big city had been robbed at gunpoint. You know where the giant landslide happened alongside the mountain just south of Santa Ana? That's the direction they ride from.
 

Jerryhatric

Member
Apr 28, 2004
3
0
Jaguar, since you seem to be the expert, please answer me on the following:

I have done extensive research on the web regarding the KDX 200 SR. I have bought a 1994 model which was imported from Japan by a company called Mitaka here in South Africa. It seems dead standard as even the exhaust is still the original (I am planning to remove the lining inside). It has 14 500km on the odometer and I bought it on 14 000km. Since then I have been running very high quality synthetic 2-stroke oil called TTS.

Since I bought the bike about 11 months ago, it won’t go into the power-band without double-clutching it up to 3 times or so. Even should it go into the power-band, the response and power is very disappointing. The low and mid range is fine but as soon as I expect the top end power-band to kick in, it puts its head between its legs and stutters.

This let me to the internet as I have little experience regarding the KDX and service for bikes in South Africa is sub-standard and extremely expensive.

Could you please inform me which of the 5 following causes is most likely causing this symptom?

1. Jetting;
2. Combustion chamber pressure leaking into the gearbox;
3. Broken and/or carbon of the KIPS;
4. Standard SR exhaust being restrictive; or
5. Deteriorating coil or CDI.

Regarding jetting (1):
I did not realise that the SR was fitted with a JE 28mm carburettor whereas the R models are fitted with the PWK 35mm. I followed the instructions step by step on the JustKDX site according to Canadian Daves’ instructions and only realised after reading Craig Erasmus’ (www.copperleife.com/craig/bikes/kdx) article on the SR that it has a different carburettor. Could I still set up the carburettor based on the specifications for the PWK?

· When I opened the carburettor I found that the needle was in the second from the top position and left it there;
· The float was slightly off and was adjusted to 16mm and parallel to the base of the carburettor;
· The pilot jet is a 45 and seems to be the correct jet as per the correction factor table supplied on the web and the riding conditions given below;
· The main jet is a 122 and according to the table should be a 148 according to the following conditions:
o Average of 82 degree F;
o 3 700 feet above sea level.
I ordered the 148 jet but will take 4 weeks to come from Japan. I suspect that the 122 was put in as some sort of a restriction/governor in the dense traffic conditions of Japan as well as for fuel efficiency.

Combustion chamber pressure leaking into the gearbox (2):
I could not find any evidence of this as the gearbox oil is as clean as when I serviced it about 300km back. There is no significant leakage of the gearbox. The only tell tale is the overflow pipe in the air box which lubricated the filter to its maximum. I did clean the filter thoroughly when I realised this. Is it normal for the overflow to drip on the filter constantly or should it only happen when the gearbox is too full?

Broken and/or carbon of the KIPS (3):
I have no clue and don’t think that the engine has ever been opened. I do not have the expertise to do this myself and will have to take the bike in for verification and repairs should this be the cause.

Standard SR exhaust being restrictive (4):
I am planning to remove the lining myself if the 148 jet does not make a significant difference.

Deteriorating coil or CDI (5):
According to Eric Gorr, a deteriorating coil would let the bike misfire at high revs. This is what the bike is doing. Initially it would run better after it was warmed up but now a day the symptom remains even if it is warmed up.

Lastly:
Does the air-screw of the PE 28mm have an o-ring and if so, what will the effect on performance be if it has been lost?

Regards,
Jerryhatric
 

hunter1

Member
Feb 27, 2004
37
0
This problem sounds similar to a problem i had on a DT 125 quite a few years ago. The culprit was a restricted Exhaust pipe that had carboned up due to age. Remove the exhaust and blow through it, there should be no restriction. Check the area where the expansion chamber joins the silencer (the smallest diameter area), this is where it normally blocks up.
 

Tico

Member
Feb 6, 2004
49
0
If that's it I suggest you to find a huge freezer. Take the pipe off, fill it with water and freeze it. Than let it melt down, when it melts the inside of your pipe should be clean.

Mine had tht problem when I got it past December and also a broken powervalve.
 

jaguar

~SPONSOR~
Jul 29, 2000
1,464
79
South America
KDX's are famous for having broken powervalves. I got tired of replacing them twice a year so I just used epoxy (the kind with metal in it is best) to glue two broken ones in place in the open position. Its best to drill a tiny hole into the bottom of them because if the glue causes an air pocket under them when installing then you'll have to push like HHEELL to get them in. See my page by clicking on my link below. To give back some low end power that you'll lose you can make your own half thick base gasket. That lowers the ports and increases compression.
Also take off the ignition cover and see if there was moisture there. Sometimes that causes it to run ratty. Check that your spark plug is clean and properly gapped.
Usually the silencers don't cause a problem. Do poke something into the end of your exhaust pipe to see if there are any obstructions.
I'm near 1000 ft and my bike likes a main jet close to 128. But since I don't like waiting for ever for a new jet to arrive, I just drilled a hole in the side of the jet and put in a tiny screw that when screwed in enough will protrude into the gas channel. That way you can just adjust it without having to replace the jet. After you see that the 148 you ordered is too big then you can modify it that way. It has to be short enough that the head is not too far out to the side of the jet because then the bowl drain would hit it which would prevent assembly.
Also water in gas will cause it to run ratty. Take the tank off, take off the cap, swish the gas around and then quickly dump it out. If corrosion comes out also then put more gas in and repeat the process till it comes out clean.
I don't remember seeing an o-ring on the air screw.
Also check your piston to cylinder clearance and piston ring end gap. Either of those being too much will lower the compression which lowers power.
I got tired of the gear oil dumping onto the filter so I connected a fatter tube onto the existing one where it ended which channeled the oil safely down to the bottom of the air box and not onto the filter.
happy mechanicing!
 
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