125-200cc Finally going from 125 to 144 to 165. Walt Rules.

In the past year I've gone from a 08 YZ125 to a 2012 Husky CR125, 144, and this weekend it'll be my first go at the 165! I'm pretty excited about it. I installed it last night and everything went pretty smoothly. Squish is set at 0.047", which is exactly what my squish was as a 144, which should be good for pump gas (Thanks Walt!). My first test of it will be this weekend - stay tuned!

I got the 165 kit from another user in a trade + cash deal. He thought it was in good condition, as did I, but I harmlessly sent it to Walt to inspect for me, thinking everything would be cool, but I just wanted to cover my bases... I was wrong - the nikisil was unstable and it needed replated in about 100 hours... So I pulled the trigger and got it replated just to be safe, since I could probably get 1000+ hours out of the re-plate with my type of riding. When it's all said and done, I saved some money...but not much. I also got the KTM200 pipe as a part of the trade, but it won't fit into the stock silencer. I'm using dremel sandpaper bands to "bore out" the silencer so it fits, but right now it's so tight that I'll never get them apart if I leave it alone.

Anyway, now everything is taken care of and I have a brand new 165 kit complete w/ KTM200 pipe ready to be ridden! The 150 kit, that I ran for about 10 hours or so, still looks brand new. I might keep it as a backup, maybe sell it, I don't know yet. Looking forward to Memorial Day!

For grinding the silencer - do you guys think a flapper wheel would work better than those cylindrical sandpaper bands? The bands apparently aren't recommended for sanding aluminum, and they get gummed up pretty quick so I'll need a lot of them.

for the pipe union, try some anti-seize on the joint before assembly, might help with install and removal. i used to do this with a titanium Silmoto exhaust system i had on my supermoto. the fit was ridiculously tight with all the bends. anti-seize worked great.

congrats on the 165, you will love it

I had to do the same thing on my 144 because the FMF pipe didn't fit the silencer. So I used one of my porting tools with 50 grit



It's a 1/4" bolt with the head cut off, and a slot cut in it to accept the sandpaper.

Didn't know that existed! Looks like this would work for me: http://www.autozone.com/autozone/ac...e-expander/_/N-274i?itemIdentifier=246376_0_0_

Fairly cheap too - $20... I expected to pay $10 for more sandpaper wheels. But I'll probably just do this. Thanks!! I just need to find one in stock somewhere.. or maybe I can rent one

Minimum size on that is 1.5". Is that not too big?

My thoughts too... this one is from harbor freight, smallest size is 1 1/8"....what's the inner diameter of the stock silencer? http://www.harborfreight.com/small-tail-pipe-expander-69550-9156.html probably kelly's photo

I'm convinced this thing will disintegrate as soon as I try to use it

Hope so - the reviews I read weren't confidence inspring. I'll take my tools and do it in the Harbor Freight parking lot, so if it breaks I can just go exchange it

Mine was 1".
Those are junk. The real ones work. The Harbor freight ones do nothing but break.

Yep 1"... 0.985" to be exact lol. Finding one that small will be a challenge

Is their any retting for the 165 kit . I will be sending my cylinder off next week.

Retting? Let me know what you mean and I will help if I can.

jetting sorry

Well I started it up yesterday. It sounds awesome. My wife said "it sounds less like a chainsaw now". lol.

Rode it finally this weekend! I was a little frustrated at first because I couldn't get it started - but it's my own fault because I flooded it from starting/stopping it too much when showing it off to people. I read others' comments about how it's hard to kick, and I don't necessairly agree that it's physically hard to kick, but I do agree that it's easier to start if you get it to top-dead-center on the 165 - whereas you don't need to worry about that as much on the 125/144.

Unfortunately, I didn't get to ride it much more than just heat cycling. But it seems promising... can't comment on the top end performance, but the bottom end is definitely more than the 144. I'll probably need a 14 tooth front sprocket now because 1st gear is completely useless unless I'm really crawling. The insurmountable gap between 2nd, 3rd, and 4th that I complained about on the 125/144 format is not an issue with the 165. Stock jetting seemed fine (so far), though I still do need to set the idle and air screws. If the jetting is off at all, it might be just a tad rich.

I don't know when I'll be able to ride it again, but I'll update when that happens. Sorry for the lame update - now that it's broken in, my next ride will be a true test!

one more week away at work & ill get to do a proper test on mine too JRod! like a kid waiting for xmas. PUMPED!