KDX200 carb question

The leak is probably coming from the fuel overflow. So either the float setting is too high, or the float valve is stuck, dirty, or worn.

As for the choke, it gets stiff at the top. Pull it a bit further and it should "click" into place at the top. There's a spring in there so it will not stay up if it's not snapped into place at the top. If it won't click at the top then take it out and clean it, inspect it, put it back if nothing looks wrong and try again. Carb rebuild kits are generally junk. Buy the individual pieces you need from sudco, pats small engine, jets r us, etc. You can get the parts for the choke if you need them, as well as jets, float valve, gaskets, and just about anything else you would need. Most the stuff is cheap.

If the choke (enricher) boot is cracked, put a cable tie around it to tighten it back up, and it will probably hold the plunger up again.

I think you got the wrong manual, the KDX-220 carb is a PWK-35, the KDX-200 carb is a PWK-38. Otherwise, the bikes are nearly identical.

220 uses pwk33 and the 200 runs a pwk35. Ron will bore either carb to 36 for you, never heard of a 38 on a kdx, unless maybe the 250 used one?

Ooops! Thanks for the correction. I only missed it by 3mm ;)

Sorry! Next time I should check my notes instead of going from memory...