top end rebuild - what parts need to be replaced

Got questions? We got answers....
Post Reply
bws2
Gold Member
Gold Member
Posts: 165
Joined: 09:30 pm Mar 15 2015
Country:

top end rebuild - what parts need to be replaced

Post by bws2 »

I'm working on a top end rebuild on my 2001 KDX200.

Aside from replacing the piston, rings, head and base gaskets, what other parts should I replace?

Should I replace the piston pin, bearing, o-rings on KIPS parts, other gaskets, or any ones?

Thanks for your help.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: top end rebuild - what parts need to be replaced

Post by KDXGarage »

Replace the piston pin and small end bearing
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
G22inSC
Supporting Member I
Supporting Member I
Posts: 513
Joined: 10:23 pm Jul 24 2006
Country: United States
Location: South Carolina

top end rebuild - what parts need to be replaced

Post by G22inSC »

Wrist pin and wrist pin bearing as well. Circlips on piston. Never reuse the old circlips.

Sorry. Looks like we posted at the same time.
Last edited by G22inSC on 04:13 pm Nov 12 2016, edited 1 time in total.
'05 Kaw KDX200 ('00 KX125 forks / '02 RM125 Showa "K2" shock)
'14 Yam YZ125(x) (oldest boy's)
'22 Yam YZ125X (youngest boy's)
'17 Yam YZ85 (soon to be FOR SALE)
'10 Honda Recon (wife's)
'08 Kaw KX65 (Sold)
'07 KTM 50SX Sr. (Sold)
'09 Yam PW50 (retired)
'97 Kaw KX250 (Sold)

Gallery

2005 KDX200 Bike Profile
bws2
Gold Member
Gold Member
Posts: 165
Joined: 09:30 pm Mar 15 2015
Country:

Re: top end rebuild - what parts need to be replaced

Post by bws2 »

Thank you Jason and G22. Is it okay to use Wiseco bearing and pin or should I use OEM from Kawasaki?
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: top end rebuild - what parts need to be replaced

Post by KDXGarage »

Yes, ALWAYS replace the circlips. Good catch.

If you have a Wiseco piston, use Wiseco rings, pin, clips, bearing.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
bufftester
Platinum Member
Platinum Member
Posts: 3455
Joined: 06:03 pm Oct 31 2012
Country: USA
Location: University Place, WA

Re: top end rebuild - what parts need to be replaced

Post by bufftester »

Piston, rings, pin, circlips, small end bearing, base and head gaskets. While it's off you should evaluate the KIPS and repair/replace as needed. And a new set of exhaust O-rings and gasket while it's all apart and clean.
bws2
Gold Member
Gold Member
Posts: 165
Joined: 09:30 pm Mar 15 2015
Country:

Re: top end rebuild - what parts need to be replaced

Post by bws2 »

bufftester wrote:Piston, rings, pin, circlips, small end bearing, base and head gaskets. While it's off you should evaluate the KIPS and repair/replace as needed. And a new set of exhaust O-rings and gasket while it's all apart and clean.
Thank you Bufftester.

I have an FMF Gnarly pipe, but all I see are two o-rings, no gasket. Does the gasket apply to a stock pipe,
or should my pipe have one too?
User avatar
doctord23
Supporting Member
Posts: 323
Joined: 01:29 pm Jul 28 2009
Country: USA
Location: NorCal

Re: top end rebuild - what parts need to be replaced

Post by doctord23 »

There is a copper crush gasket that goes in the opening before the pipe.
You may need to remove the old one if it had one.
Thegasket is important since the pipe has a lot of vibration and can damage the head if there isn't a wearable surface installed.
My Team Green:
2002 KX-KDX 220
2000 KDX 220
2003 KLX 300 DS
1988 White KDX 200C3
1984 KX500 (original owner)
1996 Honda Magna V4
2017 Honda Africa Twin DCT
Post Reply