Throwback - *EX* '92 Kawasaki KDX 125 SR - Part III - Fitting '03 Kawasaki KX125 exhaust pipe and muffler

To complete the KX look of my KDX125 I decided to fit also exhaust pipe and muffler from '03 KX125 to it. Exhaust pipe itself did not require any modification other than making a small dint for the kickstarter with bit of heat and gentle hammering. Most work went into designing a new adapter and flange that would combine both KX and KDX methods of fixing exhaust pipe to the cylinder. Otherwise I just utilized old KDX125 front bracket and made a new simple rear bracket from sheet of steel and added few steel spacers to securely fix the exhaust pipe. Short piece of silicon radiator hose fixed with hose clamps made sure that exhaust fumes would not escape between pipe and muffler.

'03 Kawasaki KX125 exhaust pipe

Test fit

Parts to fit '03 KX125 exhaust pipe to KDX125

Main dimensions of adapter

Main dimensions of flange

Test fit before paint

'91 KX125 reed valve and Keihin PJ 36 mm carb

Final form

End of story