How to video: Tear down a 95/06 KDX200/220 motor all the way

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sparkingdogg
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How to video: Tear down a 95/06 KDX200/220 motor all the way

Post by sparkingdogg »

Hi guys and girls, I have posted a video on youtube regarding the complete tear down of an H series KDX motor. It's a little over an hour long and covers every aspect including tricks and tools. It's always nice to see it done before you tear in yourself, with this as a reference you can skip around to each component as needed or watch the whole dog gone thing before you start. Hope it helps someone out!

<a href=" 1</a>

<a href=" 2</a>

<a href=" 3</a>
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
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sparkingdogg
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Post by sparkingdogg »

looks like my hyperlink doesn't work, sorry! :roll:

part 1:



part 2:



part 3:

1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
sexpanther34
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Post by sexpanther34 »

Sweet, I'll be using this over winter, thanks for saving me from a few headaches.
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sparkingdogg
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Post by sparkingdogg »

you are welcome. and if you break anything i have parts for sale :wink:

i am a power seller on ebay and do it full time. just sayin'!
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
sexpanther34
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Post by sexpanther34 »

Haha, my complete rebuild is going to go Waaay smoother now! Throw in 2 day shipping and you get all my business.
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Griffbones
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Post by Griffbones »

Sparkingdogg! Man I bought some KDX parts from you this last year. I am the guy in Red Oak that you had your buddy deliver the parts to. Glad to see you on here man! We will have to meet up for a ride sometime, I work in Council Bluffs so we are not far a part. :grin:
'83 CR60R Fully restored
'97 DR350 (407cc)
2005 KX85 (103.5cc)
2006 KDX 200 (Bone stock other than Jetting, Gnarley woods, Turbine Core II)
2007 250 XC-W (SX head)
dfeckel
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Post by dfeckel »

Very cool of you to post such a useful video, Sparkingdog. And thanks for the parts, too! You're my KDX parts go-to guy on e-bay.

Speaking of which, you don't happen to have a shifter shaft for an '87 KDX 200, do you?
David Eckel
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Velocity_Stack
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Post by Velocity_Stack »

Sweet love!

Watched the first one so far, but it's time for bed, so I'll save the next 2 for tonight when I'm at work.

:supz:
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sparkingdogg
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Post by sparkingdogg »

>|<>QBB<
sexpanther34 wrote:Haha, my complete rebuild is going to go Waaay smoother now! Throw in 2 day shipping and you get all my business.
all the small stuff ships 2-3 day priority mail/first class, big stuff is generally parcel post but faster service is available for a fee.
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
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sparkingdogg
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Post by sparkingdogg »

>|<>QBB<
Griffbones wrote:Sparkingdogg! Man I bought some KDX parts from you this last year. I am the guy in Red Oak that you had your buddy deliver the parts to. Glad to see you on here man! We will have to meet up for a ride sometime, I work in Council Bluffs so we are not far a part. :grin:
kool beans! :grin:

my buddy "sarge" that dropped off the parts got a new job as a backhoe operator, his boss has 80 acres and rides, so i may have a new riding area next spring! we have a buddy out by beebeetown but it's not a great place to ride unless you are street legal and don't mind some gravel (i hate gravel myself, too much dust). i will be doing some dual sporting next year for sure. btw i grew up in council bluffs :wink:
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
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sparkingdogg
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Post by sparkingdogg »

>|<>QBB<
dfeckel wrote:Very cool of you to post such a useful video, Sparkingdog. And thanks for the parts, too! You're my KDX parts go-to guy on e-bay.

Speaking of which, you don't happen to have a shifter shaft for an '87 KDX 200, do you?
thanks for the business!!

it was easy to shoot the vid, no problem.

sorry... no air cooled kdx parts at all.
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
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sparkingdogg
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Post by sparkingdogg »

>|<>QBB<
Velocity_Stack wrote:Sweet love!

Watched the first one so far, but it's time for bed, so I'll save the next 2 for tonight when I'm at work.

:supz:
shouldn't you e working when you are at work??? :rolleyes:

haha
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
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Post by Slick_Nick »

All 3 parts added to my favorites! :D
'00 KDX 220R
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sparkingdogg
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Post by sparkingdogg »

:razz: kool
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
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Post by Fletch »

That was funny, I enjoyed the vids
learned something too!
:partyman:
Fletch
89 kdx 200 with 99 rm125 forks
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Post by mattnzl »

Very helpfull for people like me who are a bit worried about tearing into the motor. Thanks!
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sparkingdogg
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Post by sparkingdogg »

>|<>QBB<
Fletch wrote:That was funny, I enjoyed the vids
learned something too!
:partyman:
kool :cool:
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
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sparkingdogg
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Post by sparkingdogg »

>|<>QBB<
mattnzl wrote:Very helpfull for people like me who are a bit worried about tearing into the motor. Thanks!
my pleasure! take your time and watch out for any small bits dropping out, and make sure you get all the shims to reinstall. follow the factory manual as far as reassembly and tolerances. and if worst comes to worst try playing the video backwards :mrgreen:
1999 KDX240 big bore street legal, 2008 KLX300R, 2002 XR250R stock, 1985 XL600R stock, 2001 KDX220 bone stock street legal, 1988 VN750 dresser, 1975 RD350 stock, 1983 GL650I Sliverwing Interstate with sidecar, 1975 Kawasaki F11 (early KDX!), about 15 other bikes that come and go!
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Post by Fletch »

>|<>QBB<
sparkingdogg wrote:>|<>QBB<
mattnzl wrote:Very helpfull for people like me who are a bit worried about tearing into the motor. Thanks!
my pleasure! take your time and watch out for any small bits dropping out, and make sure you get all the shims to reinstall. follow the factory manual as far as reassembly and tolerances. and if worst comes to worst try playing the video backwards :mrgreen:
Just don't freak out when you clearly hear "Paul is dead, Paul is dead" coming out of the backwards audio.......
Fletch
89 kdx 200 with 99 rm125 forks
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David_L6
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Post by David_L6 »

Good stuff! Thanks for taking the time to video the tear down and thanks for posting it for all to see.
2000 KDX200 / 2002 CR250 / 2003 CR250 / 2008 TT-R230 / 2011 Brute Force 750 / 2012 Brute Force 750 EPS
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