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piston change

Posted: 03:31 pm May 01 2014
by splashcroft
hi all,
i was thinking of changing my kdx 220 back to a four stroke but have had so much fun on it the last few rides i have grown to love it.
i bought the bike last year and it has no history, i want to do a few mods, mainly suspension for my bulky holiday weight that seems to last all year.however i must priorities. i think i better change the piston out to be on the safe side.
ok now for the main questions,
basically how do i change the piston?
i intend to buy a wiseco piston and new rings to give myself piece of mind, however after reading the cyclepedia manual it only describes the whole engine dis-assembly. i'm pretty sure it can be made simpler to change the piston out. will the tolerances for stock be the same if i fit the new piston? i am also after a step by step guide to changing it if anyone has the time to jot it down. want to save a bit of dosh doing it myself and like to get to know the bike better by working on it myself.
alas one more question, running in procedure/ warm up before riding rather than just kicking and going with a wiseco?

thanks everyone

Re: piston change

Posted: 05:00 pm May 01 2014
by diymirage
once you have tackled the KIPS actuator it is all common sense and (IMHO) no instructions are needed
in short, you pull the head,, disconnect the KIPS actuator (support the rod and keep in mind this is lefthanded tread)
pull the jug off and you are home free

just to be clear, a new piston will include a new set of rings

just curious, where are you from ?

Re: piston change

Posted: 07:57 pm May 01 2014
by Joshmcmillan
Tolerances should be on the box when you buy the piston.

For run in, let it warm up, constantly blipping throttle at low revs, once warmed up (feel top of radiator and cylinder) then turn it off. Leave it a few hours. Repeat 3-4 times.
After that, warm it up, take it for a 15 minute ride just loading it up, never let it idle,,don't rev the hell out if it.
Cool it down. Warm it up, then take it for a ride and thrash the hell out of it.

piston change

Posted: 10:42 am May 02 2014
by scheckaet
check my sig for how to. there are a few key points you MUST pay attention to when removing the kips. :wink:

piston change

Posted: 11:42 am May 02 2014
by pumpguy
As has been posted many times, do yourself a favor and GET A MANUAL. With one misprint about KIPS assembly, it has everything you will need to know about this bike.

One recommendation not shown in my manual is to install the wrist pin snap rings with their opening at the top or bottom. The idea being that when located this way, the opening will be in line with the reciprocating forces. If located at either side, these forces could cause the ring to close up, and possibly come loose. A remote chance I admit, but best not to take any chances.

Re: piston change

Posted: 03:28 pm May 02 2014
by splashcroft
thanks for all the advice. i'm from the uk. i have the cyclepedia manual but only really shows complete engine disassembly rather than just just what is required.
ok one last question. i am not sure if it has been re-bored having not stripped it down yet so don't want to get the piston yet. if i measure the diameter of the cylinder what should i allow for clearance?
diameter of cylinder - clearance = piston size required
cheers all