I'm usually a post ***** on forums but I just realized I haven't posted anything on this site. I have been bleeding it for info on my current purchase/build. First off, this bike is for my son-in-law. I bought it in an 'almost' stock condition. It was modified just enough to not run correctly. The p.o. thought that they knew how to mod a carb. That didn't work out so well for him. I rode it about 200 feet, turned around, and rode back. It was that bad. Anyway, I took it home and ripped it apart. I took the suspension to ESP in Tujunga, CA and had them re-valve and re-spring the front and rear. I tore into the carby with a jet kit from Procycle. I tapered the new needle just a little so the transition would be smoother. I started with their suggested jet sizes which were pretty close. I did a lot of searching on this forum for tips/tricks. I had a DG exhaust from a few years ago that I bought off ebay to try and make work on a DR200. I wasn't going to work for wifey's DR so I put it away. As weird as it sounds, the DG was made for a KLX250. What's the chances of that? I swapped the tires to offroad worthy tread and changed the gearing to 13/47. New chain was in order too with a couple of extra links. I knew the stock airbox/snorkel was an issue from all the chat about it on here and could see why once I pulled it apart. I decided to try my own 'mod' to the box and it turned out perfect. Pretty crisp low end and rips past 80 on the fwy. After 80, it was still pulling but the bike starts a bit of wobble because knobbies just aren't the best for hwy riding. The bike is a hoot to ride now. I played around yesterday on it and put it through it's paces. Bangin hill climbs, jumps, wheelies and sliding it sideways. Unfortunately, with all that playing around, I came up a bit short on fuel. I was WOT several times throughout the day. I was 20 miles from any gas stations in the middle of the hills. I was with a couple of riders so I wasn't too worried. I did start coasting down the trails though. I made it out and put 2.06 gallons in my tank. I think that's pretty close. I bought an IMS tank today.

As purchased

Didn't last long..

Had some tires from other bikes

My own airbox mod. Works perfectly. Ya, I studied a little flow dynamics in school. Not sure if it helped my cheap decisions.

Ready for a 120 mile loop in the hills.

Passed testing! A little shy on power to wheelie through the mud puddles at 40.

 

Looks good, your mod might not work so great on a water crossing if she goes down.
Your picts didn't show the muffler. Where is it? I think it fell off!

 

The open airbox is only an inch or so below the original line of entry. If the bike is down to that last inch.. we've got bigger problems. The bike won't be a cross country/BDR bike anyway so I'm not too worried about it. I've done 3 BDR's on my 701 riding 2up with the wife. It's much more suited for long distances,

exhaust tucked in neatly.