91 200 progress

Got questions? We got answers....
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

91 200 progress

Post by JZ05220r »

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.
Attachments
8726742D-FDA9-44DB-AEE7-7640EDD35C3C.jpeg
8726742D-FDA9-44DB-AEE7-7640EDD35C3C.jpeg (3.1 MiB) Viewed 242993 times
D9D2B18B-DF08-4E95-9BBD-F7F8B54BC5DE.jpeg
D9D2B18B-DF08-4E95-9BBD-F7F8B54BC5DE.jpeg (1.91 MiB) Viewed 242993 times
D093AC19-B4B7-4CCA-9D95-BB767449ACB0.jpeg
D093AC19-B4B7-4CCA-9D95-BB767449ACB0.jpeg (1.99 MiB) Viewed 242993 times
5BF00E70-0DC0-4F74-B7E1-4BBFE841EB11.jpeg
5BF00E70-0DC0-4F74-B7E1-4BBFE841EB11.jpeg (3.39 MiB) Viewed 242993 times
198E1059-3703-4F7D-BBBF-5A7BB0298C6C.jpeg
198E1059-3703-4F7D-BBBF-5A7BB0298C6C.jpeg (1.62 MiB) Viewed 242993 times
2005 KDX220r 1991 KDX200 2022 KTM 500excf
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: 91 200 progress

Post by SS109 »

Looking good! You said you couldn't get the rear pipe mount to fit... do you have a damper/mount for that point?
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

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.
2005 KDX220r 1991 KDX200 2022 KTM 500excf
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: 91 200 progress

Post by SS109 »

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.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 91 200 progress

Post by KDXGarage »

Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

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.
2005 KDX220r 1991 KDX200 2022 KTM 500excf
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

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.
Attachments
709F90C7-DD1D-4DB5-BBCE-4C6DED9C9D04.jpeg
709F90C7-DD1D-4DB5-BBCE-4C6DED9C9D04.jpeg (2.23 MiB) Viewed 242937 times
09F53E55-B993-46F7-B2A7-C31A7F26119F.jpeg
09F53E55-B993-46F7-B2A7-C31A7F26119F.jpeg (2.34 MiB) Viewed 242938 times
2005 KDX220r 1991 KDX200 2022 KTM 500excf
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: 91 200 progress

Post by SS109 »

Awesome!
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
User avatar
Goat
Supporting Member III
Supporting Member III
Posts: 720
Joined: 03:22 pm Oct 22 2019
Country: USA
Location: Clinton, WA

Re: 91 200 progress

Post by Goat »

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
95 KDX200
22 KX250
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

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
2005 KDX220r 1991 KDX200 2022 KTM 500excf
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

Here’s a few pics of the state the bike was in when I got it.
Attachments
7742C750-70CE-4E6F-B5C8-64639DFB700B.jpeg
7742C750-70CE-4E6F-B5C8-64639DFB700B.jpeg (3.42 MiB) Viewed 242910 times
DD6417C6-4556-4712-959A-4814976453D7.jpeg
DD6417C6-4556-4712-959A-4814976453D7.jpeg (3.17 MiB) Viewed 242910 times
C2EC5C19-D380-4709-BCEB-486AAC29D328.jpeg
C2EC5C19-D380-4709-BCEB-486AAC29D328.jpeg (3.36 MiB) Viewed 242910 times
2EA61775-F454-4CB6-BA0D-3EFEE70D99D1.jpeg
2EA61775-F454-4CB6-BA0D-3EFEE70D99D1.jpeg (3.67 MiB) Viewed 242910 times
E70729C1-2122-4B17-B365-3804F72FDE85.jpeg
E70729C1-2122-4B17-B365-3804F72FDE85.jpeg (3.92 MiB) Viewed 242910 times
2005 KDX220r 1991 KDX200 2022 KTM 500excf
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

More
Attachments
8CA8CD58-D259-442A-9648-FE17CD8EB13D.jpeg
8CA8CD58-D259-442A-9648-FE17CD8EB13D.jpeg (4.37 MiB) Viewed 242910 times
F67E64C6-5BF8-4A63-B61B-1BC0D75CC8DA.jpeg
F67E64C6-5BF8-4A63-B61B-1BC0D75CC8DA.jpeg (4.15 MiB) Viewed 242910 times
7CA3BE8D-7845-4E84-965A-FEDCFDA8D406.jpeg
7CA3BE8D-7845-4E84-965A-FEDCFDA8D406.jpeg (2.91 MiB) Viewed 242910 times
2005 KDX220r 1991 KDX200 2022 KTM 500excf
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

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.
2005 KDX220r 1991 KDX200 2022 KTM 500excf
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: 91 200 progress

Post by SS109 »

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.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

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
2005 KDX220r 1991 KDX200 2022 KTM 500excf
JZ05220r
Supporting Member II
Supporting Member II
Posts: 564
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: 91 200 progress

Post by JZ05220r »

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
Attachments
C9664CEE-F5EA-43A3-B4A0-A91D611158CB.jpeg
C9664CEE-F5EA-43A3-B4A0-A91D611158CB.jpeg (2.83 MiB) Viewed 242625 times
2005 KDX220r 1991 KDX200 2022 KTM 500excf
User avatar
bufftester
Platinum Member
Platinum Member
Posts: 3455
Joined: 06:03 pm Oct 31 2012
Country: USA
Location: University Place, WA

Re: 91 200 progress

Post by bufftester »

Nicely done
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 91 200 progress

Post by KDXGarage »

Daaaaammmnnn ! Looks great! You did a great job of getting her back together. Congratulations on your effort paying off.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: 91 200 progress

Post by SS109 »

Now that is some awesome work! Bike looks super sweet! :supz:
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
John_S
Gold Member
Gold Member
Posts: 875
Joined: 06:59 am Jan 27 2017
Country: US
Location: Florida

Re: 91 200 progress

Post by John_S »

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