Project KDX 220R - The Rebuild
- Sapphire
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- ihatefalling
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- Mr. Wibbens
- KDXRider.net
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All that primping...
Ya think he's gonna ride it??
Ya think he's gonna ride it??
Warning! This member tends to use sarcasm as a regular form of communication. If a post seems offensive, before you panic and fly off the handle, re-read the post and imagine it being said with a sideways grin.
((Bike Profile))
((Pics))
FIVE OUT OF FOUR PEOPLE DONUT UNDERSTAND FRACTIONS
((Bike Profile))
((Pics))
FIVE OUT OF FOUR PEOPLE DONUT UNDERSTAND FRACTIONS
- Sapphire
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- Supporting Member II
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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........
"Growing Old is Mandatory, Growing Up is Optional"
2008 KLX450R
2008 DRZ400SM
2005 KDX 220R
1985 KDX 200A3
2005 KLX 125L (SONS)
2003 KTM 50SX Pro Jr
B Senior # 254/0092
http://sponsorhouse.loopd.com/Members/R ... fault.aspx
Thanks to my 2008 Sponsers:
Dunlop, SteelMX, Amsoil, Simpson, Pro Works Racing, Pro Moto Billet, SLAP Energy,Boyesen, Rhino Stands, SixSixOne/SunLine Moto for your support.
John W Read Jr
2008 KLX450R
2008 DRZ400SM
2005 KDX 220R
1985 KDX 200A3
2005 KLX 125L (SONS)
2003 KTM 50SX Pro Jr
B Senior # 254/0092
http://sponsorhouse.loopd.com/Members/R ... fault.aspx
Thanks to my 2008 Sponsers:
Dunlop, SteelMX, Amsoil, Simpson, Pro Works Racing, Pro Moto Billet, SLAP Energy,Boyesen, Rhino Stands, SixSixOne/SunLine Moto for your support.
John W Read Jr
- Sapphire
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- Supporting Member II
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I was thinking about the radiator cap. Its 5 years old...The porting is Fredette, Head & Carb is RB
"Growing Old is Mandatory, Growing Up is Optional"
2008 KLX450R
2008 DRZ400SM
2005 KDX 220R
1985 KDX 200A3
2005 KLX 125L (SONS)
2003 KTM 50SX Pro Jr
B Senior # 254/0092
http://sponsorhouse.loopd.com/Members/R ... fault.aspx
Thanks to my 2008 Sponsers:
Dunlop, SteelMX, Amsoil, Simpson, Pro Works Racing, Pro Moto Billet, SLAP Energy,Boyesen, Rhino Stands, SixSixOne/SunLine Moto for your support.
John W Read Jr
2008 KLX450R
2008 DRZ400SM
2005 KDX 220R
1985 KDX 200A3
2005 KLX 125L (SONS)
2003 KTM 50SX Pro Jr
B Senior # 254/0092
http://sponsorhouse.loopd.com/Members/R ... fault.aspx
Thanks to my 2008 Sponsers:
Dunlop, SteelMX, Amsoil, Simpson, Pro Works Racing, Pro Moto Billet, SLAP Energy,Boyesen, Rhino Stands, SixSixOne/SunLine Moto for your support.
John W Read Jr
- fuzzy
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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.
'91 KDX 200 Project $300 KDX
'95 KDX 200 Project $600 KDX
'94 WR 250 Always a project
'95 KDX 200 Project $600 KDX
'94 WR 250 Always a project
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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
"Growing Old is Mandatory, Growing Up is Optional"
2008 KLX450R
2008 DRZ400SM
2005 KDX 220R
1985 KDX 200A3
2005 KLX 125L (SONS)
2003 KTM 50SX Pro Jr
B Senior # 254/0092
http://sponsorhouse.loopd.com/Members/R ... fault.aspx
Thanks to my 2008 Sponsers:
Dunlop, SteelMX, Amsoil, Simpson, Pro Works Racing, Pro Moto Billet, SLAP Energy,Boyesen, Rhino Stands, SixSixOne/SunLine Moto for your support.
John W Read Jr
2008 KLX450R
2008 DRZ400SM
2005 KDX 220R
1985 KDX 200A3
2005 KLX 125L (SONS)
2003 KTM 50SX Pro Jr
B Senior # 254/0092
http://sponsorhouse.loopd.com/Members/R ... fault.aspx
Thanks to my 2008 Sponsers:
Dunlop, SteelMX, Amsoil, Simpson, Pro Works Racing, Pro Moto Billet, SLAP Energy,Boyesen, Rhino Stands, SixSixOne/SunLine Moto for your support.
John W Read Jr
- Slick_Nick
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- Slick_Nick
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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!
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!
'00 KDX 220R
- Indawoods
- Creator and Founder
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- Joined: 09:59 am Jun 12 2003
- Country:
- Location: Midwest
All that work and you didn't paint the frame?
*** Administrator //***
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
-
- Supporting Member I
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- scheckaet
- KDXRider.net
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- Location: edmond oklahoma
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+
looks great noneless...but could have been even more better, i only give you an A, not an A+
02 KX 200 hybrid: RB head and carb
Sold ☹ DRZ 400 SM
bike build: http://www.kdxrider.net/forums/viewtopi ... ike+stable
bike profile http://www.kdxrider.net/forums/viewtopi ... 0709#30709
newb info: http://www.kdxrider.net/forums/viewtopi ... 57#p117919
jetting guide: http://www.kdxrider.net/forums/viewtopi ... 105&t=1156
Sold ☹ DRZ 400 SM
bike build: http://www.kdxrider.net/forums/viewtopi ... ike+stable
bike profile http://www.kdxrider.net/forums/viewtopi ... 0709#30709
newb info: http://www.kdxrider.net/forums/viewtopi ... 57#p117919
jetting guide: http://www.kdxrider.net/forums/viewtopi ... 105&t=1156
- Slick_Nick
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- Indawoods
- Creator and Founder
- Posts: 9951
- Joined: 09:59 am Jun 12 2003
- Country:
- Location: Midwest
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....
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....
*** Administrator //***
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
****'95 KDX 200/****
"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "