exhaust is against the rear shock coil

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exhaust is against the rear shock coil

Postby rofti » 03:50 pm Aug 12 2018

hallooooo.

i bought a kdx200. upon arrival in the garage, i serviced the shock. upon installation, i find that the exhaust is touching the shock coil. it sems that both items (like everything else on the bike) is stock standard.

surely, this is not healthy.

do i need to bend the exhaust "hangers"? if so, how can i do it without causing a weak spot? (buying a fmf may be the quickest but not the cheapest option. i still need to learn to ride this thing before i make it stronger/spend money on it.)

thank you
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Re: exhaust is against the rear shock coil

Postby Jason » 05:11 pm Aug 12 2018

I would check to see if the pipe and spark arrestor are mounted crooked, or the pipe may be bent, causing it to not line up properly.

Also, check the parts diagrams to make sure you have all the OEM parts that are used to properly mount the pipe.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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exhaust is against the rear shock coil

Postby pumpguy » 07:59 pm Aug 12 2018

Any possibility you have H vs E Series parts possibly mis-matched?

The exhaust routing for these 2 KDX versions are different, due primarily to different frames.
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Re: exhaust is against the rear shock coil

Postby Jason » 08:51 pm Aug 12 2018

83?
93?
2003?

Which year KDX200??
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Re: exhaust is against the rear shock coil

Postby rofti » 10:56 pm Aug 12 2018

it is a 2006 model.
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Re: exhaust is against the rear shock coil

Postby Jason » 02:20 am Aug 13 2018

Can you post pics of the problem, along with the mounts?

If the correct parts are used, then I can't imagine it not being bent or installed improperly.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Re: exhaust is against the rear shock coil

Postby rofti » 11:09 pm Aug 13 2018

Jason wrote:Can you post pics of the problem, along with the mounts?

If the correct parts are used, then I can't imagine it not being bent or installed improperly.


Thank you for the effort.

Until I figure out a better way to get photos on board, here are onedrive links of the mounts and of the shock.

Image
Image
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Re: exhaust is against the rear shock coil

Postby rofti » 11:09 pm Aug 13 2018

Image
Image
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Re: exhaust is against the rear shock coil

Postby rofti » 11:10 pm Aug 13 2018

Image
Image
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Re: exhaust is against the rear shock coil

Postby Jason » 12:38 am Aug 14 2018

Check the front of the pipe to see if it is bent. The lower, front mount looks a little off. Loosen them up and readjust if you can, but you are going to have to make sure the pipe is not bent.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Re: exhaust is against the rear shock coil

Postby rofti » 11:32 pm Aug 14 2018

Thank you, Jason. I loosened the nuts and manipulated the whole system a bit. It moves away without stressing the metal. It seems that some spacers at the muffler will be a more permanent solution.
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Re: exhaust is against the rear shock coil

Postby Jason » 01:52 am Aug 15 2018

Good. Check the diagrams and also, look on Google images for images of other peoples bikes to see how everyone else's bike looks.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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