So stoked to get this bike in the woods. I'm a new 2T owner. Just started riding 4 years ago and I just hit 53. I'm coming off a WR250R so pretty excited to ride this baby! I thought I was going to do more dual sport riding but it's just too much fun riding trails all day. I'm not very good but, I sure have fun!
So I get it home. Take it around the neighborhood, come back and notice it it's leaking where the pipe meets the engine. Looks like from the bottom. It's a Gnarly Woods pipe.
I'm hoping it's an easy fix. I really don't want to buy a new pipe.
If you want to buy o-rings somewhere else, just make sure they are the correct size (3.0 mm x 39 mm, as shown in the part number, 670E [30] [39]. Viton probably is what is needed, but not Buna I think. Just because it's 3 x 39 doesn't mean it will last long. There are MANY kinds of o-ring materials.
If it still leaks or you have the cash to throw at it, get new springs, too. Remember that almost every part was made around the spring or summer of 2002.
Re: New 2003 KDX 200 WI Rider
Posted: 10:31 am Mar 10 2020
by sangle333
Thanks KDXGarage!
I'm fine buying OEM.
So, just so I understand correctly.
1. buy two new o-rings, 2. buy a new gasket 3. buy new springs
Q: I did some digging last night...should I buy some gasket sealer? Permatex?
Re: New 2003 KDX 200 WI Rider
Posted: 11:23 am Mar 10 2020
by KDXGarage
If the pipe is not bent causing it to misalign, then it should not leak with just the o-rings and some grease.
Over time,the o-rings shrink or get damaged, causing the leaks. If someone keeps riding it like that, the steel pipe beats against the aluminum cylinder making the fit looser and looser.
I'd get new o-rings and the copper crush gasket and see how it goes. The springs may be OK.
WAIT:
Pipe Spring/O-Ring Kit - 011311
I had these in the back of my mind, but was not sure if they worked, but the o-rings are the same. The springs ARE NOT the same.
Thank you! I'll try the quick fix with o-rings and gasket.
One more newb question. What kind of grease should I use?
Re: New 2003 KDX 200 WI Rider
Posted: 04:13 pm Mar 10 2020
by kdxsully
Any high temp grease should do you. Get some marine/off-road grease while you’re shopping if you don’t have it already.
Re: New 2003 KDX 200 WI Rider
Posted: 06:27 pm Mar 10 2020
by KDXGarage
I think molybdenum disulfide may be mentioned in the manual. I can't remember, don't have mine handy.
I have used Bel-ray and Maxima on bikes with good success, usually just put a dab of that on it, but a stop at any auto parts store will get you a tub for half price and be enough to last for years and years.
Re: New 2003 KDX 200 WI Rider
Posted: 07:26 pm Mar 10 2020
by bufftester
Moly-B will work, doesn't take much, you can even use petroleum Jelly to hold them in place. Welcome to the forums btw. Some splooge leaking there is normal over time, jetting will help reduce it .
Re: New 2003 KDX 200 WI Rider
Posted: 10:08 am Mar 11 2020
by sangle333
TY for the suggestions - kinda comforting to know that it's normal. :)
Re: New 2003 KDX 200 WI Rider
Posted: 10:23 am Mar 11 2020
by KDXGarage
The cheapie solution is to take it apart, clean it and slather it up with silly-cone and see if it will stop it from leaking.
Re: New 2003 KDX 200 WI Rider
Posted: 06:02 am Mar 15 2020
by PolarWhiteC
I am in Wisconsin as well, where are you?
Re: New 2003 KDX 200 WI Rider
Posted: 11:34 am Apr 25 2020
by sangle333
PolarWhiteC wrote: 06:02 am Mar 15 2020
I am in Wisconsin as well, where are you?
I'm in Oshkosh. Where are you?
Re: New 2003 KDX 200 WI Rider
Posted: 08:12 am Apr 26 2020
by John_S
A dab of high temp grease like the guys mentioned has worked every time for me with new orings.
Taking off and replacing the pipe is an easy job but check out this short video. There’s a couple of helpful hints about the mounts and the joint between pipe and silencer.
It’s possible the bike will even run better. A bad enough leak at the head pipe can draw outside air in and make the jetting feel inconsistent.
