KDXRIDER.NET

I have a 2001 KDX200 that has the original piston in it.

I'm planning on doing a top end rebuild, but I've never done one before.

Can you guys tell me what parts I'll need to order?

Also what tools will I need to do this job?

You should buy the Cyclepedia service manual
http://www.cyclepedia.com/online-manual ... ice-guide/

Probably the most important thing to have is a service manual. This gives you all the information you need to work on your bike.

In addition to a new piston and gasket set, I would suggest you consider getting the cylinder re-plated. I was pleased with Millenium's work. I recommend you send your new piston with the cylinder so the plater can use YOUR piston to size the clearance. The other option is to have the plater furnish the piston and size your bore to the piston they furnish.

From what has been posted on this site, you're okay with an OEM piston if it's a 200. If it's a 220, you want an
aftermarket forged piston.

For re-assembly, you'll need a torque wrench. You'll also need a torque wrench adaptor to tighten the cylinder base nuts. Motion Pro makes this tool, their # 57-8134. I've found it handy for other uses besides torquing cylinder base nuts.

pumpguy wrote:Probably the most important thing to have is a service manual. This gives you all the information you need to work on your bike.

In addition to a new piston and gasket set, I would suggest you consider getting the cylinder re-plated. I was pleased with Millenium's work. I recommend you send your new piston with the cylinder so the plater can use YOUR piston to size the clearance. The other option is to have the plater furnish the piston and size your bore to the piston they furnish.

From what has been posted on this site, you're okay with an OEM piston if it's a 200. If it's a 220, you want an
aftermarket forged piston.

For re-assembly, you'll need a torque wrench. You'll also need a torque wrench adaptor to tighten the cylinder base nuts. Motion Pro makes this tool, their # 57-8134. I've found it handy for other uses besides torquing cylinder base nuts.

Thank you, Ced64K and Pumpguy. These are great suggestions. I'll make sure I have a manual before I start this job.

Ditto on the manual. I like the Cyclepedia online version so I can enlarge the photos on my iPad (old eyes). I also have a printed version though. I did a top overhaul on my 220 after I purchase just so I would kno do sure what was in it. I did not have it replated but should have. It wasn't long before I had to take it apart and have the cylinder replated by Mellinium.

doakley wrote:Ditto on the manual. I like the Cyclepedia online version so I can enlarge the photos on my iPad (old eyes). I also have a printed version though. I did a top overhaul on my 220 after I purchase just so I would kno do sure what was in it. I did not have it replated but should have. It wasn't long before I had to take it apart and have the cylinder replated by Mellinium.

Thank you, doakley.

I can't believe this post isn't more well known... http://www.thumpertalk.com/topic/657765 ... to-kdx200/

When I did mine, i had this thread open on the laptop and my factory service manual right next to it, I can confirm that all of the steps are completely accurate, no real need for the manual... even the torque values match the FSM lol Makes the job pretty easy and straightforward.

Well that's a great thread with nice clear pics.
i thought the white stuff was dried grease and scraped it off
thanks mark

Tyl3r wrote:I can't believe this post isn't more well known... http://www.thumpertalk.com/topic/657765 ... to-kdx200/

When I did mine, i had this thread open on the laptop and my factory service manual right next to it, I can confirm that all of the steps are completely accurate, no real need for the manual... even the torque values match the FSM lol Makes the job pretty easy and straightforward.

Hey thanks Tyl3r for sharing that link. It will be very helpful when I finally get started on this project.

bws2 wrote:Hey thanks Tyl3r for sharing that link. It will be very helpful when I finally get started on this project.

happy to share!