KDXRIDER.NET

hi guys

i have a problem and probably a silly question

kawasaki 200 kdx 2000 mod,where the exhaust meets the engine i have oil leaking there and can see one of the orings is damged and broken and basically hanging out

question is how do i replace it? how does the exhaust fit onto the motor? are there bolts im missing because all i can see are two springs

any help advice would be much appreciated

The springs are all that hold it.

4 bolts and 2 springs. Two are holding the silencer on, take it off by unbolting and sliding it back out of the header pipe. Expansion chamber has two bolts, one on top near the end of the kick starter (its two pieces of metal with a rubber cushion between them) and the other is on the right front down tube just in front of the frame hoop( metal with a rubber cushion). Take the springs off, then those two bolts and slide the exhaust out. Change o-rings and copper crush gasket and reinstall in reverse order.

ok thanks will do that

how many o rings does it have and are they the same size? and the copper crush gasket,is it the same size as the o rings?

do i ask the guy at spare shop for "copper crush gasket"?

thanks for the help

When you are at the shop you can look at the parts diagrams with the sales guy. The copper washer goes between the end of the pipe and the cylinder. The o-rings go in grooves in the end of the pipe. It'll all make sense when you take the pipe off. Often the copper gasket gets stuck in the cylinder but you can pop it out with a little screwdriver. It is a good idea to put a generous layer of high-temp RTV gasket maker on the o-rings before sliding the pipe into the cylinder.

thanks guys

at least i know what to look for now

will post success or failure over the weekend

i had the same problem with my 96...well, almost
i had replaced the pipe on it about 2 years ago and it was starting to leak at the same spot

a quick inspection told me my springs were loosing its tension (at only 17 years old...go figure)
and the from bolt/rubber/bolt had snapped loose (now its bolt/rubber bolt))

i found some stronger springs and that fixed it for me

can you buy those springs at spares shop? and if so what do you call them over the counter?

not the ones i used...they are an exclusive poultry item ;)


but im sure any good spring will do

hi just brought 2005 kdx200 noticed that pipe was leaking so pulled out expansion chamber and noticed that the two o'ring groves were empty (did not see any copper washer though). Easy to pull of chamber though not rocket science, from memory only one spring and one rubber mounted bolt then work expansion chamber loose from cylinder and silencer (this does not kneed to come off). You should see two groves in the end of the pipe, cylinder end, these should have O'rings in them, mine didn't, fortunately I had the original pipe that still had the o'rings which I used. No more leak sweet. Scale of difficulty 1 out of 10 and I have little mechanical ability.

If you only had 1 spring and one dampened bolt then you are missing 1 of each. There should be 2 springs on the pipe at the cylinder, one damper bolt at the bottom of the pipe under the large bend, and one on top of the pipe near the kickstarter.

This seems like a good place to ask my question.

I'm in the process of making a order, with out disassemble first.

I have a FMF Woods pipe and it leaks at the cylinder too, drips down on the pipe.

Does this aftermarket pipe use the same oem o-rings and gasket? How about the oem springs too?

I know on my E-series with an FMF I used the stock crush gasket and O-rings. I used FMF springs but only because my originals were shot.

Thanks for the quick reply.

same crush gaskets (the copper ones) and if it has the grooves for them , then the same o-rings.

A lot of poeple will put a thin coat of rtv sealant around the neck of the pipe (where it goes into the cylinder) to help seal it up aswell

bufftester wrote:same crush gaskets (the copper ones) and if it has the grooves for them , then the same o-rings.

Well, I guess I better pull the system off and see if the grooves are there.

Mighty expensive o-rings.

Thanks again to all that have posted.

For O rings, you might try your local bearing distributor. They usually have O rings in stock. Take your pipe with you when you go.

Be sure you ask for VITON O rings. They are good for 400 degrees F, and are recommended for use with petroleum products. Buna-N O rings are also recommended for use with petroleum products, but are only good for 225 degrees F.

Since you only need 2, they might just give them to you rather than going through the order entry process. I lucked out that way once.

Don't try Neoprene O rings from your local hardware store. They won't hold up.

As a follow-up to my last post, and because I found I needed some, I tried to follow my own advice and locate these o rings. I found it was a lot more difficult than I thought, but did finally locate some. These are equivalent to Kawasaki P/N 670E3039.

If anyone needs some, I can offer them @ $5.00 each plus $3.00 shipping and 7% tax for Illinois buyers. Sorry, USA only for now.

I can be reached at oakservcs@aol.com.

I will also post this in the FOR SALE section.