Exhaust O Rings and Gaskets

[bergilong]

The exhaust gasket and o rings (where the pipe meets the jug) were blown on my KDX, so I looked at how much new ones would cost. To buy OEM, the two o rings would be $9 each and the springs were $3 a piece.

I couldn't find an aftermarket o ring and spring kit for the KDX, but I found an FMF one for a 1995 KX125. It was only $10. Sure enough, it fit. I had to buy the OEM copper gasket, but I still saved $15.

I got both the o ring and spring kit and the gasket from Motosport. The shipping was cheap as well. I'm pretty sure you can get it for about the same price on partzilla, unless the prices have changed.

Here's the OEM gasket part #: 11009-1995
http://www.motosport.com/oem-parts/part ... 11009-1995

O ring and spring kit: http://www.motosport.com/fmf-oring-pipe ... source=pdp

You must buy both the o ring and spring kit AND the OEM gasket. You need to replace both.

Also, the gasket has a flat and rounded side. The rounded side goes towards the cylinder and the flat side goes towards the pipe. Be sure to take any broken parts of the old gasket out and clean the mating surface of both the pipe and jug to ensure that you get a good seal.

I hope this helps someone save some money, it's ridiculous how much OEM parts cost.

I also have a picture of the old and new exhaust o rings and gasket:

[KDXGarage]

Good idea.

Here;s some info from partzilla:

This Kawasaki 670E3039 O RING is used on these models and components:

1987 KX125-E2 KX125 MUFFLER
1988 KX125-F1 KX125 MUFFLER(S)
1989 KDX200-E1 KDX200 MUFFLER (KDX200-E1)
1989 KX125-G1 KX125 MUFFLER(S)
1990 KDX200-E2 KDX200 MUFFLER (KDX200-E2)
1990 KX125-H1 KX125 MUFFLER
1991 KDX200-E3 KDX200 MUFFLER (KDX200-E3)
1991 KX125-H2 KX125 MUFFLER
1992 KDX200-E4 KDX200 MUFFLER(S)
1992 KX125-J1 KX125 MUFFLER
1993 KDX200-E5 KDX200 MUFFLER(S)
1993 KX125-J2 KX125 MUFFLER
1994 KDX200-E6 KDX200 MUFFLER(S)
1994 KX125-K1 KX125 MUFFLER(S)
1995 KDX200-H1 KDX200 MUFFLER(S)
1995 KX125-K2 KX125 MUFFLER(S)
1996 KDX200-H2 KDX200 MUFFLER(S)
1996 KX125-K3 KX125 MUFFLER(S)
1997 KDX200-H3 KDX200 MUFFLER(S)
1997 KDX220-A4 KDX220R MUFFLER(S)
1997 KX125-K4 KX125 MUFFLER(S)
1998 KDX200-H4 KDX200 MUFFLER(S)
1998 KDX220-A5 KDX220R MUFFLER(S)
1998 KX125-K5 KX125 MUFFLER(S)
1999 KDX200-H5 KDX200 MUFFLER(S)
1999 KDX220-A6 KDX220R MUFFLER(S)
1999 KX125-L1 KX125 MUFFLER(S)
2000 KDX200-H6 KDX200 MUFFLER(S)
2000 KDX220-A7 KDX220R MUFFLER(S)
2000 KX125-L2 KX125 MUFFLER(S)
2001 KDX200-H7 KDX200 MUFFLER(S)
2001 KDX220-A8 KDX220R MUFFLER(S)
2002 KDX200-H8 KDX200 MUFFLER(S)
2002 KDX220-A9 KDX220R MUFFLER(S)
2003 KDX200-H9 KDX200 MUFFLER(S)
2003 KDX220-A10 KDX220R MUFFLER(S)
2004 KDX200-H10 KDX200 MUFFLER(S)
2004 KDX220-A11 KDX220R MUFFLER(S)
2005 KDX200-H11 KDX200 MUFFLER(S)
2005 KDX220-A12 KDX220R MUFFLER(S)
2006 KDX200H6F KDX200 MUFFLER(S)

In short:
1987 - 2000 KX125
1989 - 2006 KDX200
1997 - 2005 KDX220R


This Kawasaki 92144-1035 SPRING is used on these models and components:

1986 KX500-B2 KX500 MUFFLER
1987 KX125-E2 KX125 MUFFLER
1987 KX500-C1 KX500 MUFFLER
1988 KX125-F1 KX125 MUFFLER(S)
1988 KX500-D1 KX500 MUFFLER(S)
1989 KDX200-E1 KDX200 MUFFLER (KDX200-E1)
1989 KX125-G1 KX125 MUFFLER(S)
1989 KX500-E1 KX500 MUFFLER
1990 KDX200-E2 KDX200 MUFFLER (KDX200-E2)
1990 KX500-E2 KX500 MUFFLER
1991 KDX200-E3 KDX200 MUFFLER (KDX200-E3)
1991 KX500-E3 KX500 MUFFLER
1992 KDX200-E4 KDX200 MUFFLER(S)
1992 KX500-E4 KX500 MUFFLER(S)
1993 KDX200-E5 KDX200 MUFFLER(S)
1993 KX500-E5 KX500 MUFFLER(S)
1994 KDX200-E6 KDX200 MUFFLER(S)
1994 KX500-E6 KX500 MUFFLER(S)
1995 KDX200-H1 KDX200 MUFFLER(S)
1995 KX500-E7 KX500 MUFFLER(S)
1996 KDX200-H2 KDX200 MUFFLER(S)
1996 KX500-E8 KX500 MUFFLER(S)
1997 KDX200-H3 KDX200 MUFFLER(S)
1997 KDX220-A4 KDX220R MUFFLER(S)
1997 KX500-E9 KX500 MUFFLER(S)
1998 KDX200-H4 KDX200 MUFFLER(S)
1998 KDX220-A5 KDX220R MUFFLER(S)
1998 KX500-E10 KX500 MUFFLER(S)
1999 KDX200-H5 KDX200 MUFFLER(S)
1999 KDX220-A6 KDX220R MUFFLER(S)
1999 KX500-E11 KX500 MUFFLER(S)
2000 KDX200-H6 KDX200 MUFFLER(S)
2000 KDX220-A7 KDX220R MUFFLER(S)
2000 KX500-E12 KX500 MUFFLER(S)
2001 KDX200-H7 KDX200 MUFFLER(S)
2001 KDX220-A8 KDX220R MUFFLER(S)
2001 KX500-E13 KX500 MUFFLER(S)
2002 KDX200-H8 KDX200 MUFFLER(S)
2002 KDX220-A9 KDX220R MUFFLER(S)
2002 KX500-E14 KX500 MUFFLER(S)
2003 KDX200-H9 KDX200 MUFFLER(S)
2003 KDX220-A10 KDX220R MUFFLER(S)
2003 KX500-E15 KX500 MUFFLER(S)
2004 KDX200-H10 KDX200 MUFFLER(S)
2004 KDX220-A11 KDX220R MUFFLER(S)
2004 KX500-E16 KX500 MUFFLER(S)
2005 KDX200-H11 KDX200 MUFFLER(S)
2005 KDX220-A12 KDX220R MUFFLER(S)
2006 KDX200H6F KDX200 MUFFLER(S)

[patreilly]

While you have the exhaust off check out FRP. He has a "power" ring that replaces that copper gasket and is supposed to provide more low end power. I think it is $9 and shipping.

[javjacob]

I put a new FMF pipe on my 2000 KDX220R and it had new o rings. The old pipe had o rings that were in bad shape. I don't remember there being a copper gasket.

[Friedom]

While you have the exhaust off check out FRP. He has a "power" ring that replaces that copper gasket and is supposed to provide more low end power. I think it is $9 and shipping.

I'd love to add some down low grunt. Didn't know it was so affordable!

"Fun Wheel Drive"

[Friedom]

I put a new FMF pipe on my 2000 KDX220R and it had new o rings. The old pipe had o rings that were in bad shape. I don't remember there being a copper gasket.

My 92 was missing the copper gasket also, unbeknownst to me. Definitely runs and sounds better with it.

"Fun Wheel Drive"

[javjacob]

I will have to get it then. Just not looking forward to removing the exhaust and putting it back on.

[Friedom]

I hear ya. It's a dance, a wiggle and a grunt getting it all lined up.
I smear a little high temp gasket maker on the o rings going in. Seems to have helped reduce spooge.

"Fun Wheel Drive"