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I should've known to swap the top end on it this spring and it definitely hurt. And the pieces are nowhere to be found....
So this is an age old question, i've searched the forum and internet and would like the opinions... I have the skills but not the big tools to split the case or the time. I know jeff fredette does some great work. The cylinder is in good shape surprisingly, it'll just need replated. Now does anyone have any experience from them. I've heard they do great porting work. Or would it be the best to split it myself over a few weeks?
Thanks in advanced.

How could you not find such a huge chunk of metal? (well, what is left of it)

It's everywhere! It blew threw the bottom i believe. I dont think that hole was factory. I definitely need advice.

WOW! Is that a hole through the crankcase halves? Tough luck.

How many hours were on the top end?

Just curious, what year and size of KDX is this?

SS109 wrote:Just curious, what year and size of KDX is this?

looks like a 220 to me


as for splitting the cases
i havent done it on a KDX (or in fact any bike in the last 15 years or so) but it isnt as hard as it sounds
most of it with common sense and the help of a manual is pretty straight forward
all the tricks are right here on the forum as are some tricks on how to get around the "big tools"

seems to me your limiting factor is time

Ouch. Splitting the cases for me was a big pain in the ass.
You can get away without buying the big tools but plan to at least buy a flywheel puller and probably a bearing extractor. You will also need a case splitter but that can be made from a all sorts of different automotive pullers (I used a harmonic balancer puller) which can be rented from an auto parts store.
If that is a hole in your case it is basically trash. I guess you could get it welded back up but I'm sure that would cost a lot. I have seen matching pairs on eBay for pretty cheap.
Also, if your skirt exploded like that there is a possibility metal got in to your rod bearing and destroyed it. You can test that without splitting the case.
If your big end bearing is shot, honestly you would probably be best off looking for a parts bike to pull an engine from.

Yes, that's a hole in the crankcase halve. The skirt exploded inside. Looks like my best option is to buy a new case or have a shop on town weld it if there's anyway of saving it.
This bike is the best bike I've ever ridden so i want to try and keep it. And it's a 2000 220.

I'd go ahead and split them yourself. All you really HAVE to have is the flywheel puller. A case splitter is nice, but in a pinch I have used a couple pieces of angle iron bolted together with some holes drilled. One that you can bolt to the end of the crank, and holes that you can put long bolts through to go into the stator cover or case bolt holes. Once you get them apart, you should be able to tell if it can be welded or not.

That sounds pretty easy Julien, I'll give that a go in the next couple weeks. I'll keep it updated as much as i can. Thanks everyone for your help!!
The top end has lots of hours on it, too many to count. It's my own fault for not doing it.

A few years ago (2008) I was in a situation where I had money but not time. I sent a trashed lower end to Fredette and asked him to make it right. He went through the whole thing, clutch and all. It cost $700.

I put the top end on. My neighbor is still riding that bike, it is going strong.

KAWASAKICHRIS wrote:And it's a 2000 220.

Sadly, I had a feeling. Another victim of the 220 stock piston. Anyways, yeah, follow JulienD's advice and see where your at.

I should've done Klee wiesco pro lite swap. the bike ran strong never had an issue. Luck only goes so far. I've heard many people falling victim to the stock piston. If i have the fund it might be in my portion to get the 70mm bore wiesco.. Any opinions on this?
Well at last I'm not totally SOL. I still got my Xr400(440 kit) still that was finished this march.

my .02: get the right tools for the job. it'll cost just as much as having a shop do it BUT
1 you will learn in the process how to do it yourself
2 you will save a few bucks vs having a shop do it
3 you will NOW the job was done RIGHT.
4 you get to keep the new tools

it's not that hard to do with the right tools, manual and time...and this website

KAWASAKICHRIS wrote:Yes, that's a hole in the crankcase halve. The skirt exploded inside. Looks like my best option is to buy a new case or have a shop on town weld it if there's anyway of saving it.
This bike is the best bike I've ever ridden so i want to try and keep it. And it's a 2000 220.

What hole are you all talking about?
the one on both side of the crank? pretty sure it's to lub the bearings...

If you look at the space between the 2 flywheels, to the left of the lower end rod bearing, you can see a black spot. I think that's the hole in the case he's talking about.

got it. looked like shadow at 1st.