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Hello KDX-riders,

my name is Manuel and I am living in Brazil. I have been riding my KDX200-H2 (1996) since 1 year. I have made my first off road experiences with her. Now I am getting better and like to climb higher …

The problem is that my engine is getting weaker.

Some friends are supposing, to install new piston rings, to clean the valves change the gear ratio by a gear rim and so one …

I have talked with the old owner of the motorbike. He told me, that the cylinder is still the original one. It was never changed, never bored, never rebuilt , ...

He only had installed a new piston and rings, more than one time.

I have talked to my mechanic. He already has had an inside into the motor.

His opinion is, that the motor is to rebuilt complete. The cylinder has scratches on the walls; the motor is very loud with a sound of a knocking piston.
Install other piston rings or clean some things will not solve my problem. The motorbike and probably the cylinder are 15 years old.

In Brazil doesn’t exist a company which has the knowledge to rebuild a cylinder. A new one costs here about 800 USD.

Where I can get in the USA a new/rebuild cylinder, already with the valves and the correct piston kit? Crankshaft, bearings, seals, piston rod, gasket set are necessary to.

Can you please tell me your experience with this spare parts.

Thanks a lot!

Manuel

i would think that everything you are asking for would be $800 usd in America as well.

Surely there is a machine shop somewhere near you that could do the work.

Hello,

here only the naked cylinder is about 800 USD...

Best regards,
Manuel

Do a search for "replate" and you should find most of your answers.

Manuel,

I believe you should be able to find some company in brazil who can re-plate your cylinder for you. Short of that, someone should be able to bore and install a sleeve.

Thanks for your first answers.
I have found two companies in Brazil:

- Retifica Rudari (Marilia - SP) - They make chrome sleeves

- Motorey (Belo Horizonte - MG) - Specialists in Nikasil™

I am just checking the prices now. With this I can handle the cylinder topic.

About the piston, I have found 4 suppliers for piston kits:
- PRO X
- TKRJ
- ATHENA
- WISECO

What kit(s) can I buy? Almost the same suppliers are available for the crank shaft kits.

Thanks,
Manuel

With the 200, a stock cast piston works just fine. Any of those pistons kits should work for you. If budget is a concern, use what you can get a good deal on. I am not familiar with TKRJ. If I had to guess, I'd say it's the same as OEM/Pro-X.

Hello,

I entered in contact with some companies which "replated" cylinders. The service is about 450 USD.
A new cylinder is cheaper.
Now I am back to my first point of view - buy a new one.
Which internet shop is reliable to buy this part?

Thanks,

Manuel

Are you suspecting a crank issue? If not then just do the cylinder/piston. 450 for a replate is high, you could check with Millennium in the States. A replate for me in Canada is about 350usd after shipping

As a last resort, you could have your cylinder bored and install a sleeve. I normally wouldn't recommend this, as is somewhat inferior to plating, but might be cheaper depending on what machine shops can do for you in your area and it WILL work. You should be able to purchase the sleeve itself for under $100 USD, and most shops should install for 2 hours shop time.

OK, when I have the final prices, I make a comparison - Sleeved in Brazil, Replated in Brazil or a new imported cylinder.

Other question:

My actually piston is a WISECO 711M0660 STD KAW KDX200 (Clearance .0020 in).
Is it really necessary to replated or sleeve the cylinder or can I simply install a bigger piston?
What are the criteria to decide this?

Best regards,
Manuel

Manuel,

If you could post some pictures of the inside of the cylinder we could advise you better on it's condition and what may or may not be necessary. Short of that, you would need to have the bore measured and see if it is within spec. These cylinders are plated, and if the plating is worn through a re-plate, sleeve, or replacement is needed.

I've decided what I will do - without any compromise.
I've just ordered a new Kawasaki cylinder, crank, valves and a forged Wössner piston.
When I have the parts together I will begin to open the motor and post some pictures.
Regards,
Manuel

Wow. If you are certain it will definitely be nice to see the rebuild. I can tell you one thing, aftermarket plating is generally superior to the factory kawi stuff. Harder, and lasts longer. A new cylinder is quite a treat though. If you're finding the cost is the same, why not, I guess?

Just visited my KDX at the mechanic. He is closing the semi new-engine. Only a few days left to go back to the woods!