IDRIDR's 2004 KDX220 Questions Thread

IDRIDR · Post by **IDRIDR** » 11:54 pm Sep 21 2014

Greetings KDX owners.
I picked up an '04 KDX220 a couple weeks ago and am going through her thoroughly first. Bike looks mostly stock and in good condition but certainly needs maintenance. The goal is to have a trail riding machine with good low end grunt.

1) It looks like it has a stock piston as it's stamped with an arrow and "C." Only pulled the head so far and will go deeper soon. Assuming the piston is stock and therefore absolutely needs replaced, do I go with Wossner or Wiseco? http://www.kdxrider.net/forums/viewtopi ... 77&t=16320

2) Carb was dirty outside but surprisingly clean inside with no varnish whatsoever. Jets are 42 pilot and 145 primary. Are these stock? [edit: yes, will follow the jetting guide.]

3) Pipes appear to be FMF torque with FMF silencer. Will be repacking the silencer.

4) The headlight is missing and the rear fender is aftermarket with no lights. I'll be looking to rewind the stator and install some good lighting. I have an extra trailtech X2 halogen that could be used.

I want to see that it runs well first then go to other items including drive train, bearings, and suspension.

Thanks!

superman27e · Post by **superman27e** » 12:20 am Sep 22 2014

Wiseco is the best, imo.

As for the jets, I believe the stock jets are 160 main and 48 slow. But since it has the fmf on it, they probably changed it to get better jetting results.

Postigo · Post by **Postigo** » 05:47 am Sep 22 2014

Hi, welcome and congrats on your new to you bike. 42/145 is the stock jetting for the kdx220. definitely she is pig rich from factory and needs to be jetted right, I'm running 38/138 and she is a wheely machine but you need to go through the jetting guide to get it run properly because it depends of your riding conditions and every bike is different.

About the pipe I have the pro circuit platinum and also have the fmf gnarly for my the pro circuit have the best performance for the 220 but it depends of your riding style and terrain.

My stator was installed yesterday after I rewound it following the Slick Nick instructions,is a great modification for about $10 and can be done in a couple of hours with the proper tools.

You need to change the stock piston for a wiseco prolite as soon as possible the factory ones tend to fail without any advice and you will end up spending a lot of money repairing the engine if it happens. Good luck

cornishwrecker220 · Post by **cornishwrecker220** » 10:20 am Sep 22 2014

I run a wossner piston in my 220 only because they are extremely well made & nobody here in the UK likes running wiseco ...something to do with them being manufactured in japan & not up to the same quality/reliability as from the USA ( you may be fine stateside ).... Pipewise I have ran the FMF gnarley (woods) with powercore 2 silencer & also the Pro Circuit platimum pipe ..my opinion for woods ( seldom getting out of 3rd or 4th gear ) you cannot beat the FMF...period ..it gives the motor an excellent smooth grunt right off the throttle with a strong mid range...if you want top end then fit the P.C pipe...another great bolt on mod is fit the carb from a kdx 200 ( pwk 35mm ) run the 220 needle with the clip in the middle ( I run 38 pilot jet & 152/155 main jet...air box lid on.. x3 1inch Uni Filter extra holes in the lid & remove the snorkel ..also running 40.1 mix ) ..you can send the 220 carb off to Ron to be modded but the 200 carb works just as well..for a little more umph I run the boyesen rad valve .

IDRIDR · Post by **IDRIDR** » 11:15 am Sep 22 2014

superman27e wrote:Wiseco is the best, imo.

Based on following this site since joining, it seems a lot of folks stateside use Wiseco. Thanks.

Postigo wrote:Hi, welcome and congrats on your new to you bike. 42/145 is the stock jetting for the kdx220. .... but you need to go through the jetting guide to get it run properly because it depends of your riding conditions and every bike is different.

About the pipe I have the pro circuit platinum and also have the fmf gnarly for my the pro circuit have the best performance for the 220 but it depends of your riding style and terrain.

My stator was installed yesterday after I rewound it following the Slick Nick instructions,is a great modification for about $10 and can be done in a couple of hours with the proper tools.

You need to change the stock piston for a wiseco prolite as soon as possible the factory ones tend to fail without any advice and you will end up spending a lot of money repairing the engine if it happens. Good luck

Thank you. I will definitely go through the jetting guide. Any suggestions on jets, needles, etc to have on hand are welcomed. I'm at 3,000 ft and typically ride up from here, sometimes up to above 10,000 but we rarely spend time at that elevation (a ridge crossing is typical). Humidity typically low. Temperatures from 40 to 90 F typical. The silencer is FMF TurbineCore 2. Reeds appear to be stock.

My riding style is like a 47 year old guy cruising trails, usually not on the faster side of our group. Targeting a setup for steep, rocky technical mountainous terrain from spring through fall, although the bike may also run some open desert in winter to early spring. I'm not looking to race. Plan to follow the stator rewind and get the new piston before riding any more. I was surprised to find a 220 with an intact piston based on all the reports here, which tells me its likely this bike doesn't have a ton of hours.

cornishwrecker220 wrote:I run a wossner piston in my 220 only because they are extremely well made & nobody here in the UK likes running wiseco ...something to do with them being manufactured in japan & not up to the same quality/reliability as from the USA ( you may be fine stateside ).... Pipewise I have ran the FMF gnarley (woods) with powercore 2 silencer & also the Pro Circuit platimum pipe ..my opinion for woods ( seldom getting out of 3rd or 4th gear ) you cannot beat the FMF...period ..it gives the motor an excellent smooth grunt right off the throttle with a strong mid range...if you want top end then fit the P.C pipe...another great bolt on mod is fit the carb from a kdx 200 ( pwk 35mm ) run the 220 needle with the clip in the middle ( I run 38 pilot jet & 152/155 main jet...air box lid on.. x3 1inch Uni Filter extra holes in the lid & remove the snorkel ..also running 40.1 mix ) ..you can send the 220 carb off to Ron to be modded but the 200 carb works just as well..for a little more umph I run the boyesen rad valve .

Thanks. Can you point me to some threads on 200 carb on the 220?

Here she is on day of pickup.

IDRIDR · Post by **IDRIDR** » 12:15 am Sep 23 2014

Is this the stock 220 piston?

Tedh98 · Post by **Tedh98** » 03:37 pm Sep 28 2014

Wiseco's have numbers/letters stamped on the top and you can usually see the machining marks on the side of the piston.

IDRIDR · Post by **IDRIDR** » 04:11 pm Sep 28 2014

Thanks. I figured out after looking at other pics it was stock and have a Wiseco ready to install now.

The KIPS parts looked okay to me:

I had the cylinder honed and was putting the power valve assembly back together and sheared holder screw with spring and ball bearing (part 13091) so will be waiting on Maw Kaw to get that one shipped. So, with time on hand, I'm going to service the wheels and suspension.

As she sat last night

Sprocket side of rear wheel looked like this:

Because the PO must have lost the collar/spacer and this is what was being used:

Where's the pulling-hair-out-of-my-head emoticon?

I was worried the hub may be damaged, but after pressing out the bearings it looks like it is largely okay.

So this morning, I found a KDX being parted out on ebay (sad thing, too, as it looked like a perfectly nice KDX out of Vancouver just being parted out...better not be stolen...that's bad Karma...but the seller 'looks' reputable) and picked up a whole rear axle assembly, CR Hi Bend bars, and a Moose skid plate that looks brand new. He also has some nice looking plastics up.

Maybe in a 2 to 3 weeks we will have a runner ready to run through the jetting guide.

So my question for today: Anyone have a kick stand for sale?

Have a good week.

diymirage · Post by **diymirage** » 07:26 pm Sep 28 2014

IDRIDR wrote:So my question for today: Anyone have a kick stand for sale?

that is too funny

Postigo · Post by **Postigo** » 08:31 pm Sep 28 2014

Diymirage you have a collection of KDX kickstands so why you don't sell one of your huge collection?

Post by **bufftester** » 02:01 am Sep 29 2014

You generally don't want to hone a plated cylinder, just so you know.

diymirage · Post by **diymirage** » 05:22 am Sep 29 2014

Postigo wrote:Diymirage you have a collection of KDX kickstands so why you don't sell one of your huge collection?

i'll sell him one allright...but it will come with a complete KDX still attached
we got a choice of green or purple, 200 or 220

IDRIDR · Post by **IDRIDR** » 08:17 am Sep 29 2014

bufftester wrote:You generally don't want to hone a plated cylinder, just so you know.

My local shop honed it, but just a very little touch up before the wiseco goes in. What are my risks?

Thanks.

Postigo · Post by **Postigo** » 10:10 am Sep 29 2014

Be carefull with your local shop the should know that honning a nicasi cylinder can damage the plating at the cylinder ports.

IDRIDR · Post by **IDRIDR** » 11:15 am Sep 29 2014

I checked with them.

They touched it up with a deglazer and not a hone. I was mistaken.

IDRIDR · Post by **IDRIDR** » 12:02 pm Sep 29 2014

diymirage wrote:
Postigo wrote:Diymirage you have a collection of KDX kickstands so why you don't sell one of your huge collection?

i'll sell him one allright...but it will come with a complete KDX still attached
we got a choice of green or purple, 200 or 220

I'll take the 220 in purple. May as well have two two twenties.

In all seriousness, I take it kick stands are hard to come by? Do they break, or just get thrown in the garbage?

Post by **bufftester** » 02:39 pm Sep 29 2014

IDRIDR wrote:In all seriousness, I take it kick stands are hard to come by? Do they break, or just get thrown in the garbage?

Lol...they are rare cuz DIY buys 'em up, just like Postigo snags every tank that comes up

Postigo · Post by **Postigo** » 02:47 pm Sep 29 2014

No worries about gas tanks any more because finally I have the green gas tank I was looking for. Trade a kickstand for a Clarke oversized gas tank.

diymirage · Post by **diymirage** » 03:30 pm Sep 29 2014

Postigo wrote:No worries about gas tanks any more because finally I have the green gas tank I was looking for. Trade a kickstand for a Clarke oversized gas tank.

funny fact, the only KDX I have that is NOT for sale has both a kickstand AND a Clarke oversized tank

not sure why the kickstands are hard to come by, it looks like most people take them off and pitch them
not sure why

3j3j3j · Post by **3j3j3j** » 06:33 pm Sep 30 2014

diymirage wrote:
Postigo wrote:No worries about gas tanks any more because finally I have the green gas tank I was looking for. Trade a kickstand for a Clarke oversized gas tank.

funny fact, the only KDX I have that is NOT for sale has both a kickstand AND a Clarke oversized tank

not sure why the kickstands are hard to come by, it looks like most people take them off and pitch them
not sure why

I am not sure either. Maybe they are loat on the trails from loose bolts?

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