DR200SE muffler?

[DR650gary]

Hi all, looking for some advice. We have a 2008 DR200SE and we want to boost performance just a tad to give some more on the highway but not loose the low down grunt (such as it is) so regearing is not really an option. I bought a spare muffler and want to modify that plus rejet a bit as required. I have removed the weld lip inside the front pipe. My wife rides this and she is approx 50 kgs so we are not looking for a major boost, just enough to get a comfortable speed on the highway. i have read about the Keintech exhaust mod but sending a pipe to the US seems a bit on the really dumb side and Cycleworks quoted $490 to make me a new one so... Anyone done something to this or a similar exhaust? What should I do. Open the end or split down the back and remove weight and baffles?

Thanks

[warewolf]

I had an '01, which I left standard so can't help you with the mods. IIRC airbox & jetting were the number 1 fixes, but never got around to it.

Mine would cruise on 115km on the flat, topped out about 125. Make sure you rev it because there is a rough spot before the top end power comes on. Only really noticed it in 3rd/4th and it would fool you into thinking you'd redlined it and change up too early... but no, it would smooth out again and rev out well. Those extra kays in 4th would then lead to a better response when you drop it in to 5th.

[MXNUT]

Hi all, looking for some advice. We have a 2008 DR200SE and we want to boost performance just a tad to give some more on the highway but not loose the low down grunt (such as it is) so regearing is not really an option. I bought a spare muffler and want to modify that plus rejet a bit as required. I have removed the weld lip inside the front pipe. My wife rides this and she is approx 50 kgs so we are not looking for a major boost, just enough to get a comfortable speed on the highway. i have read about the Keintech exhaust mod but sending a pipe to the US seems a bit on the really dumb side and Cycleworks quoted $490 to make me a new one so... Anyone done something to this or a similar exhaust? What should I do. Open the end or split down the back and remove weight and baffles?

Thanks

Hi Gary, i had the similar complaint with my wifes DR200 and after much research i decided to go the Kientech way.
I got the jet kit / new needle and the exhaust extension sent over for just under $80.00 NZ including freight. Then it is just a matter of buying the correct size holesaw to cut out the original outlet and welding the new extension in. I did this myself as i had access to a gas welding plant but if you dont, then any exhaust shop should do it for a reasonable price.

The thing that appealed to me about Jessies kit was that the needle and jets and exhaust mod had been all matched to each other so there was no jetting hassles.
You also have to remove the flap from the top of the airbox.

This gave the bike about another 5 mph top speed and actually improved fuel economy at higher speeds ( 60mph ).

[DR650gary]

Thanks for that. I had looked at the Keintech system but wondered if there were any backyard genius's that knew an alternative. I did think that removing some of the interior may also reduce weight as it does weigh a ton. May also just grab a small straight pipe and get a mid pipe made.

I have emailed Keintech but no reply so far.

Cheers

[DR650gary]

Hi Gary, i had the similar complaint with my wifes DR200 and after much research i decided to go the Kientech way.
I got the jet kit / new needle and the exhaust extension sent over for just under $80.00 NZ including freight. Then it is just a matter of buying the correct size holesaw to cut out the original outlet and welding the new extension in. I did this myself as i had access to a gas welding plant but if you dont, then any exhaust shop should do it for a reasonable price.

The thing that appealed to me about Jessies kit was that the needle and jets and exhaust mod had been all matched to each other so there was no jetting hassles.
You also have to remove the flap from the top of the airbox.

This gave the bike about another 5 mph top speed and actually improved fuel economy at higher speeds ( 60mph ).

Do you still have the bike? There is an endcap on the muffler so I assume you removed that, cut the welded tip off, cut the new hole, welded the larger diameter tip on, the refitted the end cap again? Do you remember the diameter of the new tip?

Cheers

[DR650gary]

Still no reply to my email to Keintech so I removed the end of the can for a look see. The outlet to the big wide world is about 15mm in diameter and the inlet about 28mm. So I will make up a new tip, possibly go through the middle of the baffles and weld it all back together. When I say I, I mean my friendly engineer mate, but I will take the bits to him. Will reuse the end cover and it should look lovely. The the jetting. Any input will not be frowned upon.

Cheers

[MXNUT]

Still no reply to my email to Keintech so I removed the end of the can for a look see. The outlet to the big wide world is about 15mm in diameter and the inlet about 28mm. So I will make up a new tip, possibly go through the middle of the baffles and weld it all back together. When I say I, I mean my friendly engineer mate, but I will take the bits to him. Will reuse the end cover and it should look lovely. The the jetting. Any input will not be frowned upon.

Cheers

Hi Garry, internal diameter of Kientech exhaust extension is 33 mm.
Cant remember what size the jets were, as they supplied both a new main jet and pilot jet.
The big thing about the kit was a needle of a different taper which from all the research i did was the big factor in getting the engine to carburate cleanly.

Go to ADVRIDER.COM and under the thumper section search for the DR200 thread.There are pages of info on the Kientech kit on there and the jet sizes are listed.

[DR650gary]

Thanks very much for that info. Will get a start on the tip tomorrow. Have started reading that thread. Up to page 85 so almost halfway there.

Cheers

Gary

[DR650gary]

Hi Guys

As you can see I grabbed the DR-Z125 Big Gun setup that was on Trademe. I worked out that it would bolt on and it did, although I needed to open the bolt holes on the header flange to fit the DR200 head exhaust studs.

Sounds good, revs well although I think it has had little impact. I think I need to install a larger main jet but will await any advice on that. I will probably return to the stock header as the ID of that is identical to the ID on the midpipe inlet. Will have to cut a bit of the midpipe and create a flange of some sort. I think the Big Gun looks good and I was able to get 70mph down the road. I weigh 105 kgs and it took about 300 meters to get to that speed. Tried all combinations, stock, stock header with a modified (open) stock exhaust plus the full Big Gun. Also tried an open airbox but that was crap mid range.


The bike starts really well with all combinations and started this am with zero choke, although it is parked in the barn but I thought that may indicate rich rather than lean.

Comments and if anyone wants the Big Gun DR-Z125 header, let me know and I'll consider any offers. It is a fraction smaller internally, 30mm not 31.5mm but that makes little difference I think. According to the Big Gun site, it is mild steel with a ceramic coatings.

Cheers

[NordieBoy]

Open airbox and up the mainjet.

[DR650gary]

Open airbox and up the mainjet.

Just a hole, or the whole lid? Have seen some postings complaining of water entry in heavy conditions with the whole lid off.

Main to??

Thanks

[NordieBoy]

Just a hole, or the whole lid? Have seen some postings complaining of water entry in heavy conditions with the whole lid off.

Main to??

Thanks

No idea without seeing the airbox.

I'd take the main up one size and see how it goes.
If it needs more than 2 turns out on the mixture screw then up another size.

If you let more air in/out then you need more fuel to compensate.

[MXNUT]

Came accross the old carb kit out in the shed today, STD main jet size was 125 and new jet is 132.5.
I remembered how the standard needle had vitually no taper at all compared to the new needle and the new needle was adjustable by raising or lowering the clip position which the old needle was not.

The other big factor was on the standard carb the fuel mixture screw was factory pre set and then covered over with a brass blanking plug.
Because this was at the bottom of the carb and is not able to be accessed with the carb in place, you cant make any adjustments.

The Kientech kit contains instructions how to modify the carb body and fit their fuel mixture screw which when the carby is back in place on the bike, is easliy adjustable and made quite a difference to the acceleration just off idle.

Took the air bod lid off completely. Wont be an issue water getting in under normal circumstances and i figured the missus was unlikely to be fjording any really deep water on it.

[DR650gary]

I am having a real problem getting the vernier in to measure the diameter of the exhaust port. Does anyone know what it is or where I can find it?

Thanks

[DR650gary]

I also thought "what the hell" and ordered the jet kit for the DR650 and the DR200. I also grabbed one for the ZRX1200 while I was at it as the seller gave me a real deal. Will advise what it comprises when it arrives.

Cheers