Kawasaki Sportsbike Riders Club - Australia - Online Forum

Hey all,

I know this isn't a dirt bike forum but help a fellow kawa rider out! I just picked up a KDX200 (The 3rd Kawa in the garage now - filling up nicely!) its got an aftermarket Pro-circuit pipe on it with a nice ding in the expansion chamber.
I've done a bit of reading (Thanks google) and theres a few techniques out there to 'pop' the dents out but I'm not sure If i really know what I'm doing and might end up making it worse so I figure it might be worth getting a pro to look at it so does anyone know any places they can recommend for pipe repairs? Preferrably VIC but I will ship it interstate and back if needs be.

Alternatively anyone else had much success with pipe repairs any fool proof methods?

Cheers!

plenty of 2 smoke fans here aggerz... even if they arent chook chasers...

obviously it would be good to bang it back out from inside.. but that isnt possible so i'm out of ideas

KDX 200 is a great little bike
Pete Gibson lives around Melbourne somewhere ,( he made his living in England making 2T pipes ) and is still doing a bit from home here . Try calling Martin from Hyside Trading 0403 836 266 and tell him what you want to get done and I am sure he will be able to sort you and the pipe out . Martin will know if Pete will do the job or who else can .
Tell him Billy sent ya .

Drill a hole in the centre of the dent, bit of wire wrapped around a short bolt with the end cut off, thread afore mentioned bolt thread through hole and pull the farker out, if it wont go heat the farker within an inch of its life before pulling.

If it works, fill the hole with weld and grind and sand flat.
Might work.

Or drill hole in opposite side of exhaust to the dent and poke in an old thick stem screwdriver with the tip flattened and hammer the carnt flat from the opposite side, then get the welder out.

Arghhhh expansion chambers

Thanks for the replies folks I've been sidetracked with a leaky fuel tank as well bloody thing!
Speaking to a mate about the tank, he offered to have a crack at fixing the dent. Figured I didn't have much to lose so I left the bike with him last week and popped in yesterday to have a look - have to say I'm bloody chuffed with the result better than I could have hoped for

apparently after a few attempts he rigged up a plugs with a valve, warmed the pipe right up with a torch then fed some air in until it got to about 100psi and it started popping out no problem.

Before:


After:
(Just needs a little buff to bring back the shine)

Well done

Bloody rippa!!!

Probably a good time to re pack the can while your at it .

The ol KDX are a pretty respectable bike. Pro circuit expansion chamber is a good combo for the 90's KX/KDX ... the originals were average at best.