If at first you don't succeed

If you have an issue and just can't seem to sort it out you should keep a few things in mind. Perhaps, that carburetor just keeps on presenting issues. No matter what you do, you just can not seem to nail down what the problem is. You try and try but although you have had it apart countless times it just keeps presenting the same symptoms. Go back to the simplest solution. Go back to the beginning and look at what you have done. Triple and quadruple check all of your adjustments. Chances are you forgot something simple. 

I took the kdx 200 apart again tonight to clear up the carb overflow issue. I found debris in there the last time and after clearing it, I didn't take the time to check the float height. I figured that, since I had been very careful when I extracted it, that it would be within spec. Fail.

It was significantly out of spec when I opened it up tonight. I am not certain that I have solved all of the issues, but the gas is no longer pouring out of the carburetor overflow line. I think it is finally ready for a test run at one of the local parks this weekend. I am hesitant to haul the bike anywhere to exciting for fear that it will fail on me and I will spend more time and more gas only to be doing repairs further from home rather than riding somewhere amazing.

We will see though. I am not sure I can resist the call of Arkansas much longer.

Here is the sight I used for a quick reference: "Method One - Measuring the Height of the Float

This method requires a set of calipers. With the carb upside down, tilt the carb until the tang on the float just makes contact with the needle rod protruding from the float valve. At this point the distance between the bottom of the float and the float bowl mating surface should be 16mm ± 1mm or 0.63" ± 0.08". Remember the carb is upside down so the bottom of the float is facing you. If the distance is out side of this range gently bend the tang and recheck. Ideally you would reassemble the carb and recheck it with the fuel level gauge. If you don’t have a gauge you’ll have to trust you set the height properly.

Measure the distance between the bottom of the float  and the float bowl mating surface (#1). The distance should equal 16 mm +/- 1 mm or .63" +/- 0.08"

Method Two - Setting them Parallel

This method is similar to the first method. It isn’t quite as accurate but works fine if you don’t have access to a set of calipers. In method one when you measure the distance between the bottom of the float and the float bowl mating surface the two are parallel to each other. If you use a straight edge for a reference, a feeler gauge works well, and place it on the float bowl’s mating surface you can visually check to see that the two are parallel to each other. It helps if you angle the feeler gauge towards the float to reduce the distance between the two a little. Tilt the carb the same way you did in the previous method and watch for the tang on the float to just make contact with the needle rod protruding from the float valve. If the two are not parallel at this point the bend the tang and recheck. Ideally you would reassemble the carb and recheck it with the fuel level gauge. If you don’t have a gauge you’ll have to trust you set the height properly."