Merged tuning advice for a '96 KDX200


Jul 11, 2006
Even tho there are other threads that have a lot of advice in bits and pieces, I thought this might be a useful thread for those with an H model KDX200 (1995-newer). The following info was assembled from information previously/separately posted to this site so I cannot vouch for it's accuracy. I do plan to use this info as a baseline for setting up my (old and used) 1996 KDX200. If anyone has comments, changes or corrections please be sure you are very clear (and it is relevant to 1995 and newer KDX 200 ONLY...) before posting here.

Carburetor Parts:
Parts, jets and needles are available from Fredette Racing or Sudco International. Better KTM dealers will also have new PWK jets.
The Kawasaki Keihin PWK carb is not identical to standard Keihin PWK carb, so be sure to mention that you have a KDX clearly when ordering parts from a non-Kawasaki vendor

FMF best all around pipe seems to be Rev pipe, aka Desert, aka -30.
Some riders prefer the FMF Torque pipe, aka Woods pipe, aka -35, if they are climbing hills a lot.
FMF Gnarly pipes: number -35 = torque, number -30 = rev
The FMF Fatty pipe is an early version superceded by the two newer "Gnarly Woods" or "Gnarly Desert" pipes.

If you ever break a fork stud, and you will, the Kawasaki part # is 172G0622. Or use Suzuki part number 01421-06208.
Or try to find some metric 6 x 1 x 32.5 steel studs.
Stock forks use .35 kg springs which are too light for average US rider.
For 155 lb rider, use.38kg springs in forks (1998-1999 Honda XR400)
For 175 lb rider, use.40kg springs in forks (2000-2002 Honda XR400)
Dennis Kirk MSR Series 69 replacement fork boots fit nicely.
EMGO fork boots are dimensionally same as original boots.

Recommend either 12/47 or 13/50

Keihin made the air screw and main jet easy to get to for a reason: Those two things are (virtually) all you need to worry about changing once your jetting is basically set up.

With FMF Fatty pipe and Boyesen reeds, try:
45 pilot, 155 main for starters, air screw at 1 1/2 out. Use DEM needle.
Try needle with clip set second from top of needle

With stock #5 slide, try a CEL or BEL needle.
Use a DEL with the #6 slide.
Use a DEK with the #7 slide.

Many 200 riders with stock motors and carbs (#5 slides) preferred the BEM (I wonder if he meant to say DEM???) needle for smoothness with the FMF k-35 pipe.

Some 200 riders preferrred CEM needles with the FMF -30's and pro circuit pipes

"Try a CEM/3 or a DEM/3 (with the stock #5 slide), or a CEK/3 or DEK/3 with a #7 slide (throttle valve). With those needles you may also need to go 1 step leaner on the main from the stock or R1173L".

Every bike is unique and will require it's OWN jetting set up!!!!!!!!!!!!!!

Standard mixture ratio - 32:1
Most common recommendation - Use a good full synthetic motorcycle premix oil at 40:1 ratio.

Power Valve KIPS:
Clean it out. Do it annually. Make sure it works smoothly.

Boyesen #607 Power Reeds are best reeds for the money.

Spark Plugs:
NGK BR8ES (stock) or BR7ES
Try NGK EG series plug - more money, runs better, longer plug life.

Michelin M12 medium rear, S12 front.
Dunlop 756.

1996 STOCK Specifications:
Model: KDX200
Price: $4,299
Engine: 2-stroke
Cooling: liquid
Valve system: 6-petal reed
Bore x Stroke: 66 x 58 mm
Displacement: 198 cc
Transmission: 6-speed
Wheelbase: 56.5 in
Seat height: 36.2 in
Ground Clearance: 13.4 in
Fuel capacity: 2.9 gallons
Weight: 223 lbs
Front tire: Dunlop 739, 80/100-21 (or Michelin 90/90-21)
Rear tire: Dunlop 739, 100/100-18 but use 110/100-18 (or Michelin 120/80-18)
Carburetion: Keihin PWK35
Slide: #5
Needle: R1174K
Pilot Jet: #45
Main jet: #160
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Jul 9, 2006
Any advice or info as far as jets or reeds for the Dyno Port pipe?

Or info about the pipe?

Great post, sorry if my questions are ignorant, I figured if somebody knew the info it'll add to the thread.

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