KDX 220R - The Rebuild - Part Two

[Slick_Nick]

I kinda got carried away bolting in things like the carb, handguards, plastics, seat, etc. So I don't have many pics of that process, but here's a big jump forward to the finished product. I modified a set of KXF fork guards instead of the '95 "slipper" style ones that would go with the forks.

[Slick_Nick]

Lets go see how we did:



Yep, it ripped! Did a bit of tweaking to the jetting and it was dialed in perfectly. Super crisp, shifted through all the gears beautifully, just awesome.

You'll notice I'm not running my UFO frame guards this time around. After a thorough bath, I noticed some wear starting on the freshly powdercoated frame. Unacceptable in my opinion, the only advantage in the coating over paint is its durability. For what I paid, next time I'll be just painting the frame instead. Powder isn't worth it. The wear wasn't too bad, so I went nuts with the clear paint protection film, all over the frame, even the plastics. Invisible and durable. Should have done that from the start, but oh well.

I also lost the Dzeus fastener that holds the left side panel on during that ride, ordered a new one from Kawasaki. It comes with the clip for the frame.

[Slick_Nick]

Believe it or not, that one ride in 2019 was the last one I would take for over a year. The bike sat on its stand, under a cover for about 18 months subsequent to that. I had winterized it of course by pulling the carb apart completely, draining the fuel, emptying the tank, putting in fresh trans fluid and pumping up the tires, I also make sure the engine is rotated to TDC if it's going to be sitting for any length of time.

This was just before putting it away in 2019.





fast forward to 2021, I now have 3.5 hours on it, and I've ridden it a whopping 3 times since this rebuild was completed! It still has the nipples on the tires, but I look forward to riding it more this summer!

Thanks for following along! I also have my KX250F rebuild which is MUCH more in depth that I'd be happy to share if you'll allow a 4 stroke build on the forum!

[TheYakk220r]

Looks amazing. Great work.
Curious about your front chain guard cover. Did you machine that?

[Slick_Nick]

Looks amazing. Great work.
Curious about your front chain guard cover. Did you machine that?

No, Its off a Yamaha something. YZ426 maybe. Thought it looked cool.

[mercenary223]

Great looking bike. Nice work and great attention to detail.

[KDXGarage]

Awesome job! It is looking terrific!

[Slick_Nick]

Thanks all! Stay tuned for the KXF rebuild.

[Two_stroke_brit]

what a great documented rebuild , loads of great pics and help there.
hi have split my cases on my 98 , how did you get the crank out of the other case half.

thanks Mark

[Slick_Nick]

what a great documented rebuild , loads of great pics and help there.
hi have split my cases on my 98 , how did you get the crank out of the other case half.

thanks Mark

Install your case splitter on the other side of the crank once the cases are apart and use it to push the crank out.

[Two_stroke_brit]

AH HA.
never thought of that .
thanks a bunch.
Mark

[Slick_Nick]

AH HA.
never thought of that .
thanks a bunch.
Mark

They come with adapters for both sides of the crank.

[John_S]

Great looking bike!! Thank you for posting that the case splitter comes with the adapters. I was wondering if it worked on both sides for the KDX.

[Slick_Nick]

The stock footpegs were tired and dull. Gave them a blasting, sharpening, and replating. Not only do they look good now, it should be much more durable than the stock silver painted finish.

[Slick_Nick]

Action shots!

[TwistedRoot]

Dang those pegs look great! Nice job.

[KDXGarage]

Looks sharp! :-)

[GATOROC]

Nice work on the pegs! I also like the action shots with the beautiful scenery as well! looking like Graham out there - now we just need to see some 3' log crossings!

[Slick_Nick]

Nice work on the pegs! I also like the action shots with the beautiful scenery as well! looking like Graham out there - now we just need to see some 3' log crossings!

I’m more into motocross these days. I think I would’ve cleared a 3’ log here by about 25’!

[lucy]

Dude, you're going crazy with that plating stuff! Eh?