92 KDX200 FMF Gold series fitment

[SpruceItUp]

Good evening! I've finally gotten the bike most of the way back together, just waiting on the rear shock to be rebuilt. Hopefully by Monday it will be done.

Anyways, I got it running, but trying to put on the expansion chamber was a pain in the rear end. I got it fitted, but the end that goes into the cylinder seems a bit crooked, and therefore when I started it up there were exhaust gases leaking from there. I put new orings and the copper gasket on before I started it. I figure the pipe is bent a bit, and it's possible it leaked before I tore the bike apart but I can't remember.

I don't feel comfortable riding it with an exhaust leak there because it minds well be an air leak as well. So I was wondering how to go about bending it back into place. Do I use heat, or do I just stick something in the end of it and pry? Just curious as I don't want to destroy the pipe as it's in decent condition, there's a few small dents but otherwise it cleaned up pretty nicely.

Thanks!

[SS109]

You can try bending it back with a round piece of wood. However, these pipes bend with any hard drop so it tends to happen again and again, IME. What I do is just add some high temp silicone sealer to the joint and let it sit 24 hours before running it. Works great as long as you're not pulling the pipe regularly.

[SpruceItUp]

You can try bending it back with a round piece of wood. However, these pipes bend with any hard drop so it tends to happen again and again, IME. What I do is just add some high temp silicone sealer to the joint and let it sit 24 hours before running it. Works great as long as you're not pulling the pipe regularly.

That's a good idea. I think I'm going to try bending it back a tad then put some sealer in there, as I can see the side of one of the o-rings if I look in where it goes.
Thanks!

[Molly's 70]

Use Permatex Ultra Black gasket sealer. It's awesome & is oil resistant.

[SpruceItUp]

Thanks for the info! I bent it back and it fits way better now, and was surprised how easily it bent . I'm still going to run to the autopart store later to get some of that permatex, as I don't have the ultrablack stuff. Then I'll fit it.

I have an 05 cr125 that also has an FMF pipe, albeit a bit smaller obviously, but I don't think it would bend that easily? The one on the 200 bent extremely easily, I just put the end of a rake with a wooden handle in the pipe and it was way easier to bend than I would've figured.