I have two KDX-200. Both jetted identical. The 96 KDX runs perfectly. The 95 runs very sluggish just off idle, and when you decel quickly the engine tries to die and does not respond to the throttle until past 1/4 throttle. I took the carb from the 96 and put it on the poor running 95 and the bike ran perfect. As a process of elimination I moved from the 96 KDX one part at a time, the main jet, pilot(slow) jet, float bowl and float valve. None of the parts moved from the 96 made the 95 KDX run good. I put in the jets, float valve and needle, from the 95 into the 96 carb and the bike ran perfect. I seem to have norrowed the fault down to something in the 95 KDX carb body itself. I took the 95 carb apart and cleaned it with carb cleaner and compressed air, but the cleaning did not help. I am not runling out that the carb has a factory defect because it had a 35 pilot jet in it when I bought it used. The previous owner may have been trying to lean out the blubery low end.
The 95 runs ok on the mid to top end. Just off idle to 1/4 throttle is where it runs poorly. The bike will not idle easily. When I put the 96 carb on it idles fine and runs much cleaner off of idle. The needle jet is set the same on both bikes so I don't think the needle jet is the problem.
I am completly stumped and would appreciate some advice on fixing the carb or a good recommendation to send the carb in for repair.
thanks