Rebuilding my 04 220

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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JFortner5
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Rebuilding my 04 220

Post by JFortner5 »

I recently picked this bike up and knew from my last 220 to get the stock piston out in a hurry. The bike seems like it's in decent shape but I have found a few things I need to address while taking it apart.


The piston in this bike was not cracked so that was good. The cylinder has a little bit of wear but it's not bad. I'll run it this season at least.

The power valve is nasty...

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Even though my piston was in one piece it was time for a rebuild. I'm not an expert at reading a piston but I think the black on the skirts is from blow by. The head has a lot of carbon in it and the top of the piston did until I cleaned it off.

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I stopped working on it for the day. My piston won't be here until Tuesday anyway. My question is do the piston kits come with a new rod bearing? Do I need one? I can't remember it's been a while since I rebuilt my other one.

I'll post this too just in case somebody new sees it but here is the stock piston out of my last 220-

Image

Get those stockers out ASAP. That last bike was running perfect and had it not been for this forum I hate to think what would have happened.






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Joey

2003 KDX 220R
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Rebuilding my 04 220

Post by canamfan »

The wiseco kit on RMATV&cycle shows piston, rings and new pin but no small end bearing, have to order separate.
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Re: Rebuilding my 04 220

Post by JFortner5 »

Is it okay to reuse it or is it best to replace it? I think I already know the answer.


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Re: Rebuilding my 04 220

Post by Tedh98 »

Definitely replace it. It is probably around $10 - it definitely isnt cost prohibitive.
Last edited by Tedh98 on 10:41 pm Feb 07 2016, edited 2 times in total.
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Re: Rebuilding my 04 220

Post by JFortner5 »

I'm not sure I need to look right now. I might as well though I need to order some front wheel bearings while I'm at it


Update- Just ordered one, I'd rather do it right. They're about $15.
Joey

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Re: Rebuilding my 04 220

Post by ecojbr »

I have re used them in a pinch. But if your waiting on piston why not spend the small amount for a great piece of mind?
04 kx220 hybrid
03 kx 250
05 kdx 200
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JFortner5
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Re: Rebuilding my 04 220

Post by JFortner5 »

All of my parts came in today. I was looking forward to coming home from work and start putting the bike back together. I opened up the piston kit and Wiseco left the rings out.

I guess it will be a few more days before she lives again.


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Joey

2003 KDX 220R
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Re: Rebuilding my 04 220

Post by TheRadBaron »

I had a Wiseco piston kit show up without rings once, too. My theory is that douchebags are ordering the piston kits, keeping the rings for a rering job, and sending the piston and box back for a full refund. Probably a lot more common with 125s than KDXs, though :roll:
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JFortner5
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Rebuilding my 04 220

Post by JFortner5 »

Your theory is probably right unfortunately. I ordered it through Amazon so they already have another one on the way. It's not really a big deal, it's pretty cold out in the garage anyway.


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Joey

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Re: Rebuilding my 04 220

Post by JFortner5 »

I'm slowly making progress. Amazon was great to deal with. The replacement came Friday and had all the parts in the box.

I got the KIPS cleaned and reinstalled last night. I just finished up getting the piston installed along with the cylinder and head. I could finish today but I'm ready to watch some racing so I'll have it running tomorrow.

I can't wait to hit some single track.


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Joey

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Re: Rebuilding my 04 220

Post by JFortner5 »

It's alive. I don't know what it is but this bike feels really strong off the bottom compared to my last one. I can be idling along in 2nd and gas it and it just goes. I almost lost it the first time I wasn't expecting it. I heat cycled it a couple times and took it for a little ride earlier.

I still have a few loose ends to deal with but I'm really happy today. It's nice to hear it come to life after rebuilding it.


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Joey

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Re: Rebuilding my 04 220

Post by KDXGarage »

Congratulations on getting it together and back out riding. :bravo:
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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JFortner5
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Re: Rebuilding my 04 220

Post by JFortner5 »

I figured I'd post a few more pics of the bike, and my riding buddy-

Image

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We are fortunate to have that little area to ride at within walking distance from our house. We have a few trails in the woods that connect us from home to that field.


I've got a few more little bugs to work out of my bike, and also to get those numbers off of it.


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Joey

2003 KDX 220R
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