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I recently purchased a complete 2000 kdx 220 motor knowing it needed some work. I have a 2006 kdx 200 and wanted to rebuild this motor in hopes of educating myself on engine rebuilds. After taking of the jug I noticed it had a chunk missing near one of the cylinder port holes. My question is if this is salvageable and if so what should I do. If not what is the best option on finding another one. Please help!

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That's pretty nasty. you could send it off to langcourt or another cylinder refurbishing outfit and have them quote you what it'd cost to fix. Worst case, it could be bored and sleeved, but I would replace it with another used/re-plated cylinder before I'd go that route.

I would assume that buying a used, worn cylinder (non-damaged) and having that replated would be a little cheaper than major repairs, followed by replating on the current cylinder.

I agree. Can't hurt to get a quote on it though.

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Thanks guys. I will get it quoted.

where is the best place to buy a used undamaged cylinder? I looked around tonight and didn't seem to find any. Are they are to come by?

Look on eBay.

ouch, looks pretty bad.
like mentioned: get a quote for repair, hunt on ebay for a better shape cylinder and get it replated.

note: did u just get the cylinder or the complete bike?
if you got the complete bike, I'd seriously consider opening the bottom end to find the missing pieces of the cylinder port...better safe than sorry. And no it's not that hard to do the bottom end.

I appreciate the comments scheckaet. I didn't get the complete bike but did get the complete engine. I don't want to get in over my head money wise. I paid $150 for the motor. Can you comment on the price point I should be looking to pay for a used cylinder. I have only seen one "new" cylinder on ebay that was $499. I am assuming/hoping used will be much much cheaper. Otherwise I am going to can this project.

Are you planning on putting this in your 200? Why not go through the bottom end, get it all fresh, and when it's complete, throw a new piston in your 200 jug and throw it on the 220 bottom? A stock rebuilt 220 is going to feel alot different than your 200. The additional displacement is misleading. The 220 is ported for low end, and feels a bit sluggish up top compared to the 200, although it does have stump pulling torque more in line with a 4t trail bike.

Somewhere around $50, plus shipping, then another $200 for a replate and $125-ish for a piston kit and gaskets.

Dooon't forget the bottom eeeeend.

Thanks Jason. I appreciate the reply.

Julien, I am not planning on putting this in my 200. It is in great shape. I was thinking of doing a kx kdx conversion possibly. But I guess I understand what you are saying. If I want the motor to feel like my 200 I should go with a 200 top end and carb? This seems to be what I have read, anyways.