Project KDX 220R - The Rebuild

Sapphire · Post by **Sapphire** » 11:30 am Apr 14 2010

Well... you about to ride her yet?? Dang, this is a great thread. I am looking forward to getting a bike to rebuild now!!!!

ihatefalling · Post by **ihatefalling** » 09:39 pm Apr 14 2010

yea....good thread.....best of luck when you get to ride her. I hope you feel it's a 10 out of 10

Post by **Mr. Wibbens** » 11:45 pm Apr 14 2010

All that primping...

Ya think he's gonna ride it??

Sapphire · Post by **Sapphire** » 08:37 am Apr 15 2010

Let us have a good list of the upgrades and the total cost...if you would! I think I am gonna try and buy a KDX in the next month or two, ride it all summer, then do this in my shop over the winter!!!!

Green Hornet · Post by **Green Hornet** » 09:36 am Apr 15 2010

FYI-With the RB Carb & your ported cylinder...You may have to fatten the Main Jet. I took mine out yesterday in the mountains, the bike was running lean & I started pissing coolant out after lugging & abusing the **** out of the clutch going up a steep, leaf ridden, rock ridden, root ridden, muddy hill. My bike has done this before but not on a cool morning with only 10 miles into the ride. Freddette advised me to throw the 160 MJ back in & play from there...By the way his porting made the 220 even more tractor like........

Post by **fuzzy** » 10:22 am Apr 15 2010

Search on here for radator cap, and look into that for your 220 heat issues. Jet main jet with plug chop.

Sapphire · Post by **Sapphire** » 11:08 am Apr 15 2010

"By the way his porting made the 220 even more tractor like........

Ron's or Fredettes?

Green Hornet · Post by **Green Hornet** » 11:40 am Apr 15 2010

I was thinking about the radiator cap. Its 5 years old...The porting is Fredette, Head & Carb is RB

Post by **fuzzy** » 12:03 pm Apr 15 2010

Like I mentioned, do a search at the top. Search for '220 AND radator cap' and there is lots of usrful info for 220 overheating. THe recommended cap is not the oem kdx cap. I can't post a link to the search results as it's an 'on-demand' search.

Green Hornet · Post by **Green Hornet** » 02:12 pm Apr 15 2010

1.6 Cap...Also I have DEVOL Rad Guards..Older Ones. Freddette also stated they may be the problem.........I guess I will have to pluck away

Slick_Nick · Post by **Slick_Nick** » 09:54 pm Apr 15 2010

I've never overheated my bike, even when it was jetted really lean.

Slick_Nick · Post by **Slick_Nick** » 12:32 pm Apr 19 2010

Well, sorry its been a few days since an update, but the bike is ALMOST DONE!!! I've spent the last few days getting it all back together, and tomorrow is the big day. I just need to add trans fluid, and coolant. Then I'm going riding!

Here are some pics of the process, yesterday's are missing, but the bike is now complete with the exception of side panels once the rads are bled. Pics will come, don't worry!

This goes back a few days, but here we go!

Got the cases back together, as you'll see later that silicone gets peeled off.

Cases together, right side ready for all the goodies:

Impeller in, new gasket on:

Shift shaft in, star detent in, kickstarter installed, and main shaft gears installed and torqued. Outer clutch basket going on.

New plates in

[IMG::]http://img89.imageshack.us/img89/2562/dsc05239.jpg[/img]

For some reason they gave me 6 springs?

Clutch complete and torqued down:

Side cover installed, clutch cover installed, water pump cover installed, and as I mentioned before the excess silicone was removed now that it was dry:

Stator installed, stock timing for now. Silicone applied where the harness enters the case as per the shop manual.

New output shaft collar and O rings

[IMG::]http://img177.imageshack.us/img177/293/dsc05244e.jpg[/img]

Piston, with rings gapped. Don't worry, I cleaned it before I put it in!

Bottom end lubed up, new base gasket installed. I used Motorex fully synthetic premix.

Cylinder on, base nuts tightened, i gave everything a generous coat of oil.

Head gasket on, and head tightened. It was upside down for this pic, I flipped it around before installing the head.

KIPS shaft showing proper alignment:

The FINAL piece!

The completed engine, showing my approval!

[IMG::]http://img197.imageshack.us/img197/2852/dsc05253g.jpg[/img]

Next, I installed the engine into the bike, installed the sprocket, and torqued all the engine mounting bolts and headstays:

Installed the chain, tightened it as per the shop manual. Old chain was on #8 to be of sufficient tightness! Torqued axle nuts, installed new cotter pin:

Installed shifter, rear brake, rads, hoses, frame guards, airbox, fender, etc.

[IMG::]http://img20.imageshack.us/img20/7399/dsc05263n.jpg[/img]

I didn't take any pics of yesterday's progress, suffice it to say that the bike is now finished. I installed my hour meter, temp stickers, carb, seat, number plates, etc etc etc... After one more check over, I'll fill the juices and give her the first kick tomorrow! Don't worry, pics and videos are forthcoming!

Post by **Indawoods** » 12:41 pm Apr 19 2010

All that work and you didn't paint the frame?

Tomm9050 · Post by **Tomm9050** » 12:51 pm Apr 19 2010

Or put on an aftermkt shift lever?

Jupiter2 · Post by **Jupiter2** » 01:19 pm Apr 19 2010

Indawoods wrote:All that work and you didn't paint the frame?

Yeah Nick I was a little curious about that too. I've been following the thread and think you did a totally awesome job and was just wondering why you chose not redo the frame?

Post by **scheckaet** » 01:39 pm Apr 19 2010

such a shame to put all of that effort into the engine and not do the same to the frame

looks great noneless...but could have been even more better, i only give you an A, not an A+

Tomm9050 · Post by **Tomm9050** » 01:47 pm Apr 19 2010

New tires? what are you running?

Slick_Nick · Post by **Slick_Nick** » 02:57 pm Apr 19 2010

Rode it yesterday, I'm a bit behind on updates here. The frame didn't get re-coated because i have frame guards for the sides, and I don't bother with a heavy skidplate thatwill trap mud, so the first log I hit would have the bottom of the frame all gouged up again.

Post by **Indawoods** » 03:07 pm Apr 19 2010

Heavy skid plate? They are aluminum!
Trap mud? It will only trap mud until you hose it off... sure beats a beatup motor with a possible hole in it from a rock.

I will say this... you are an odd one Nick....

Tomm9050 · Post by **Tomm9050** » 03:08 pm Apr 19 2010

How did it run?

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Project KDX 220R - The Rebuild