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I find a lot of spooge dripping out of the pipe at the exhaust port. I replaced that copper ring gasket not too long ago; so it should be good. So why is it all of a sudden starting to drip spooge?

check your reeds for leaks, cracks...
air filter clean?
using different oil? different gas brand?
jetting right on? http://www.kdxrider.net/forums/viewtopi ... 105&t=1156
it can take awhile for spooge to accumulate in the muffler and finally drip...

Are the two o rings on the pipe good?

I had this problem did you buy a genuine kawasaki copper gasket? I first got a cheap one from ebay and it didnt work, got one from kawasaki and it fixed it for a few weeks untill I left my exhaust bung in the exhaust after washing started up and it went again! doh!

Dekon wrote:Are the two o rings on the pipe good?

Oh I see. Didn't even know there are o-rings there. I guess they're shot.

terminatr wrote:

Dekon wrote:Are the two o rings on the pipe good?

Two? I only see one.

I have an E and it has two o-rings where it inserts into the cylinder.

Yes. I see now there are two o-rings on the pipe and also a copper gasket at the end of the pipe.

It is usually a good idea to put a layer of hi-temp RTV over those o-rings and let it set up over night after installation.

My pipe is a FMF. Does it use same size o-ring as stock?

yup

Darn. Those OEM o-rings are $10 a piece. The part number shows it is 39mm.
Is OEM the only option?

FMF makes them. Check here: http://www.rockymountainatvmc.com/p/43/ ... st+o+rings

Not sure if the KDX is listed, maybe you can cross reference from a KX.

Do your springs feel like they still have enough tension? Might be worth getting a new set if they are feeling weak.

They look very rusty, but there's still a lot of tension. Very tough to install the springs, using a vice grip.

Maybe the springs are bad. I went ahead and got new aftermarket springs and put 'em on. They are crazy strong. They were much, much more difficult to put on than the rusty stock ones. I suspect this is the main problem.

get yourself a spring puller will make things much easier

http://uk.images.search.yahoo.com/image ... d58iqJ3tiP

I replaced the spring. Now, no more leak.

I didn't replace the seals because I'm too cheap.

terminatr wrote:I replaced the spring. Now, no more leak.

I didn't replace the seals because I'm too cheap.

Did you replace the "spring" or the "springs"? There should be two of them.

Yeah, got 'em both two pieces of spring replaced. The new one is really tough to get on. It's aftermarket
and shaped different. First time, my vise grip slipped off the spring, and I went flying backward. It took alot of he-man muscle to get it on.

Open the throttle more