hi everybody

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o/d
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hi everybody

Post by o/d »

bought a 2002 kdx220 in need of a lot of work early december 2016.
been at least 20 years since i've had a 2 stroke.

i'm about to split the cases. bought RM case splitter & crank puller.
my 1st time splitting cases.

cylinder was repaired by millenium technologies & looks great.
'02 kdx220, '01 drz470e/sm, '04 drz434s, '02 fxst, '80 kz750
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KDXGarage
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Re: hi everybody

Post by KDXGarage »

Welcome to the forums.

Congratulations on your KDX.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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doctord23
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Re: hi everybody

Post by doctord23 »

Welcome
My Team Green:
2002 KX-KDX 220
2000 KDX 220
2003 KLX 300 DS
1988 White KDX 200C3
1984 KX500 (original owner)
1996 Honda Magna V4
2017 Honda Africa Twin DCT
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bufftester
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Re: hi everybody

Post by bufftester »

Welcome. Make sure that the piston is not OEM while it's all apart. Tons of info here to help you out. There is nothing on these bikes that can't be worked on with just a modest set of shop tools and a small handful of special tools. Good luck and show the pics!
o/d
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hi everybody

Post by o/d »

finally uploaded some pictures. most people like pictures...

Image

as it sits, or has been sitting for some time now. and yes, the pink helmet is mine
chassis pretty much ready to go. all bearings replaced and/or greased as needed.

Image

most of it on the shelve. just waiting to get the crank back & i can start my 1st attempt at re-assembling a bottom end.

Image

the crank. i checked run out. wasn't too bad. still decided to send it out. they will remove the bearing, which saves me about $60 for the tool to remove it.
the other bearing was still in the case. i removed it with some threaded rod.
i pressed crank out on a press at work.

Image

new tusk impact rear rim with buchanan spokes. oem had a crack on rim. missing & frozen spokes too. yippee!

Image

piece of what i'm assuming was a piece of a previous piston wedged in con rod.

Image

some debris found on bearing after splitting cases.

Image

more debris & it doesn't look like seal was put in right.

that's where i'm at now. want to try to get crank seals & bearings in today perhaps.
thanks for letting me share, and hope it's not too long or too many pictures.
'02 kdx220, '01 drz470e/sm, '04 drz434s, '02 fxst, '80 kz750
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KDXGarage
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Re: hi everybody

Post by KDXGarage »

Did the stock piston break?

Thanks for the pictures.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
o/d
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Re: hi everybody

Post by o/d »

Jason wrote:Did the stock piston break?

Thanks for the pictures.
If I had to guess, I'd say yes. Looks to me like a piston came apart at some point and previous owner put in a wiseco while ignoring damaged cylinder.

Bike ran fine during test ride. Motor didn't make any odd noises that I noticed.
'02 kdx220, '01 drz470e/sm, '04 drz434s, '02 fxst, '80 kz750
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KDXGarage
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Re: hi everybody

Post by KDXGarage »

Wow, another awesome previous owner
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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