top end reassembly

[javjacob]

I am ready to put the motor back together on my 2000 KDX220R after getting the cylinder re plated. This will be my first motor rebuild so I want to make sure I do everything right. I got the gasket surfaces cleaned up but is there a way I need to prep it before I set the new gaskets on? Do I just wipe it down with carb cleaner or rubbing alcohol?
My cylinder I got back from Millennium is all cleaned up and all the gasket surfaces are textured now. So I imagine they will seal to the gaskets no problem but the crankcase area is smooth so I am thinking it needs to be squeaky clean?
I still need to get a repair manual and a torque wrench adapter for the cylinder nuts.

Cant wait to get the motor all finished up and back in the freshly powder coated frame.

[doakley]

You should have received very specific cleaning instructions from Millennium when you got the cylinder back. Follow them. If you did not, go on their website and read them there.

[bufftester]

When you get the cylinder back, a good bath in hot soapy water followed by blowing out with compressed air. Then brake cleaner and a scotchbrite pad gets the gasket surfaces nice and shiny clean.

[javjacob]

I didn't see anything on the website and didn't get any instructions. I will wash the cylinder bore out with soapy water and a scotch brite pad. The surfaces where the gaskets seal I just wipe clean with brake parts cleaner to make sure there is no residue?

[doakley]

Here you go, from their website:

http://www.millennium-tech.net/vidplaye ... l278d71bf6

[diymirage]

heres a tip for reassembly

dont worry about timing the subvalves
drop them in, and slide in the actuator rod that connects the two valves
then grab a pair of pliers and lift the valve up about half an inch

this will place the rod in a recces in the valve and allow you to turn the valve to match up all the timing marks

[javjacob]

Thanks for the link and the tips. Hoping I can get it assembled today.
Does anyone know the torque specs for the 4 cylinder nuts? I know the head nuts show 18 ft lbs. also what about the reed bolts and power valve cover bolts?

[bufftester]

Just soapy water for the cylinder, don't run a scotchbrite pad in your cylinder bore. Use the pad on the gasket surfaces. Cylinder nuts same as head, 18 ft/lbs. 52 inch/lbs on the covers. You really should invest in a service manual...there are a lot of moving bits and pieces in the KIPS that need to go together correctly.

[javjacob]

I plan on getting a service manual but cant get one today. I checked the ring gap, got the rings on the piston and got the piston installed.
My next question is which way do the gaskets go on (which side up/down) and do I need any kind of gasket sealer to go on the gaskets? Sorry for all the questions but this is my first time doing a top end, I have been watching YouTube how to videos all day it seems like.

[bufftester]

Gaskets go on dry and will only fit one way as long as your locating pins are installed

[javjacob]

Ok thanks! I never thought of the set pins. So far this has been easier that I expected it to be.

[Tedh98]

So far this has been easier that I expected it to be.

Gotta love two strokes.

[javjacob]

I got the cylinder and head on. Nuts are only finger tight for now until I can get a torque wrench adapter. I want to torque the cylinder first.

[javjacob]

So far this has been easier that I expected it to be.

Gotta love two strokes.

Yeah I love the simplicity of 2 strokes. I still don't think I am brave enough to do a 4 stroke top end.

[Jaguar]

If you want to re-use the base gasket after your next reassembly then coat it with engine oil first.