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Got the engine back in the 91 today as well as the fmf/dep pipe install. Had to tweak the fmf pipe a bit in order to get it through the guide hole. Can’t get the rear mount on the fmf to fit. Hoping I can get by without it. A few more pics to come.

Looking good! You said you couldn't get the rear pipe mount to fit... do you have a damper/mount for that point?

SS109 wrote: ↑01:24 am Jan 25 2023 Looking good! You said you couldn't get the rear pipe mount to fit... do you have a damper/mount for that point?

I do but it was to long from point to point. I was gonna gonna leave it unattached but I’m going to make a homemade one just for peace of mind. I already had to bend the pipe in a few spots to get the end spout through the frame hole centered where it connects to the silencer. It was way too low.

I think you'll be fine without it but it sure wouldn't hurt to have it. You could open up the hole on the pipe to accommodate the extra length of the mount/damper. BTW, are all your mounts/dampers the same? They are supposed to be the same at all three points.

Looking good!

https://www.partzilla.com/product/kawas ... c5ce06366c

KDXGarage wrote: ↑11:11 pm Jan 25 2023 Looking good!

https://www.partzilla.com/product/kawas ... c5ce06366c

Thanks and I actually had another. I managed to modify it to make it work.

SS109 wrote: ↑10:23 pm Jan 25 2023 I think you'll be fine without it but it sure wouldn't hurt to have it. You could open up the hole on the pipe to accommodate the extra length of the mount/damper. BTW, are all your mounts/dampers the same? They are supposed to be the same at all three points.

Yes they are, I managed to modify the mount. It was too long point to point and the rubber part stuck out too far which would have messed with my alignment at the exhaust port. What I did is rip the rubber off. Then I sanded the rubber down until it wasn’t as tall. I cut the bracket done slightly as it hit the pipe then I glued the rubber piece back on with some high strength loctite super glue. Came out great.

Awesome!

That looks sweet. Is the problem that they don’t make a pipe setup specifically for the 91?
PS. Just noticed the rubber on shift lever! Is that stock? ….talk about old school…. Don’t want any unnecessary scuffs on those boots : )

Goat wrote: ↑12:19 pm Jan 26 2023 That looks sweet. Is the problem that they don’t make a pipe setup specifically for the 91?
PS. Just noticed the rubber on shift lever! Is that stock? ….talk about old school…. Don’t want any unnecessary scuffs on those boots : )

Thanks man! Actually this was for the 91. I have both e and h model Kdx with fmf pipes. From my experience the fmf pipe never fits as good as the stock pipe on these 2 strokes. Still have to work out some fitment issues on my h model. Here’s the link to the shift lever. https://www.ebay.com/itm/115647099425?m ... media=COPY

Here’s a few pics of the state the bike was in when I got it.

More

All that is is left is the wheels, carb and air box, and rear shock, then I will be finished. I’m debating whether or not I should start off with the stock jetting with the R1173n needle or go straight with the DGK needle and slightly leaner jets. I have everything needed for both combos. I only rode the bike once before tearing it apart and because of the poor condition of the engine prior, I was never able to establish a baseline.

DGK needle? Not familiar with that one in KDX's. CEK (what I run) and DEK are pretty popular.

Anyway, you can get a ballpark figure by what others have run in your area. Elevation and temp are the two big factors. Then, follow the jetting guide here on the forum to really dial in your jetting for the best power.

Yes I have read good things about the dgk and cgk. I understand that the dek and cek will work well for the RB carb but I’m hoping to use my 36mm pwk. Most of the info I found on the dgk was from this post but their are others. viewtopic.php?t=4140

It’s basically done now. Just need some rear brake parts and a chain. I learned a bunch throughout this process thanks to all the knowledgeable people here. Thank you

Nicely done

Daaaaammmnnn ! Looks great! You did a great job of getting her back together. Congratulations on your effort paying off.

Now that is some awesome work! Bike looks super sweet!

Amazing looking bike! I enjoyed following along on the build.