2000 KDX 220 top end

javjacob · Post by **javjacob** » 04:10 am Nov 09 2016

I am going to do the top end on my KDX 220 and was wanting to get a repair manual for all the torque specs. I have heard there is more than 1 version and I don't know which one to get. I keep reading about a "supplement" version.

This is the first motor I have ever tore into so any extra help or tips are more than welcome.

javjacob · Post by **javjacob** » 04:19 am Nov 09 2016

I already removed all the KIPS covers and removed the reverse thread shaft nut while holding the shaft still so it didn't move and break anything. I also removed the 4 nuts and removed the cylinder. I already removed the head a week or 2 ago and sent it to RB. I am going to send the cylinder to Millenium to get replated since the cross hatching is wore gone. I plan to let them clean the KIPS so I don't have to mess with it. I got a new Wiseco piston and all the gaskets. Just letting everyone know where I am at currently in this project.

One more question... how do I remove the old gasket material?

Post by **KDXGarage** » 05:37 am Nov 09 2016

OEM coating does not have the massive bear claw scratches that replated cylinders show. Don't mistake it for being so worn if you are looking at pics of aftermarket.

Spray gasket remover and a gasket remover tool?

javjacob · Post by **javjacob** » 02:11 pm Nov 09 2016

I guess all the manuals are close to the same? I will get some gasket remover and a tool, I didn't know there was such a thing. This is my first time ever tearing into a motor.

Post by **Tyl3r** » 03:52 pm Nov 09 2016

Get a new razor blade with a handle attached to it and scrape the gasket material with that. Just take a little care not to scrape/gouge the machined surface with it.

For a manual, check this thread out... http://www.thumpertalk.com/topic/657765 ... to-kdx200/

I can verify that all of the torque values are correct (I checked with my FSM). The process is also spot on. The photos for each step make it very simple. I did the top end on my KDX over this past winter. It was the first top end that I had ever done. I did the whole thing using the link above, bike is currently together and running awesome!

Post by **KDXGarage** » 04:49 pm Nov 09 2016

https://www.craftsman.com/products/craf ... craper-set

https://www.permatex.com/products/gaske ... c-formula/

CAL-kawi · Post by **CAL-kawi** » 02:31 pm Nov 10 2016

Careful with the gasket cleaner though; it will strip the paint off your cylinder and make a mess with paint flecks everywhere. Keep the excess wiped off, including the inside surface of the intake area, kips cover etc.. Aesthetis aside, I remember being concerned about all the loose flecks getting sucked in on startup.

javjacob · Post by **javjacob** » 12:48 pm Nov 11 2016

Thanks for the tips. I might call a friend of mine who is a mechanic and see if he can make sure I don't mess anything up. I am nervous about messing something up with the gaskets or the piston rings.

Post by **KDXGarage** » 01:00 pm Nov 11 2016

Install gaskets dry.

KDXohio · Post by **KDXohio** » 02:45 pm Nov 11 2016

It's really a pretty easy job. Just take your time and don't force anything back together gently compress the piston rings before installing the cylinder once they're compressed enough the cylinder will drop right on. Gaskets, as long as the surfaces are clean and you put them in the right direction not much to screw up there.
Goodluck!

Post by **KDXGarage** » 03:04 pm Nov 11 2016

Like a lot of things, look on Youtube for KDX videos.

KDXRIDER.NET

KDXRIDER.NET