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I am working on rebuilding a motor to put in a hybrid. To make a long story short I have to top ends. One from a 2000 220 and the other from a 200. I am using the 220 head on the left. Two questions:

1. What are the two tapped holes on near the hoops for the exhaust springs. They seem to not be on the 200 head (on right) or any other heads that I have seen online. I can't find any mention of them in the manual either.
2. Where can I buy the plug that is missing right below where the pipe goes. I don't see it in the manual. The plug is on the 200 head shown on the right.

I think, that the two holes are for an SR bike with a different pipe mounting flange set up.

And I think you will find the plug to be a pipe plug and could be found at most hardware stores or parts stores.

What do you mean by"SR bike"

Thanks for the information.

SR was a different version of the KDX that was sold outside of the US and is a street legal bike. I don't know for sure that the holes are for that but I think I remember someone looking for a flange mounted pipe in the past.

Just compare the two exhaust ports and make sure the KDX pipe will fit in good and you should be fine.

that's what I would say

on a side not, how in the world did the barrel get so clean while the kips is so nasty?
seems fishy to me

My 220 has those same threaded, unused holes as well.

Sent via morse code

cyl. on left was most likely replated.

kdx633 wrote:cyl. on left was most likely replated.

yeah, but would you reassemble it with that kips gear so full of grime you cant even see it has teeth ?

that seems fishy to me

Yes you are correct. The one on the left was re-plated. It had a busted port due to the infamous grenaded cylinder. I sent it off myself but did not take pictures before. So, I was to cheap to pay the $50 dollars to get it reassembled. I was missing the plug mentioned above.

As far as the "grime" on the kips on the left cylinder. That is grease. I believe the manual said to grease that gear. Am I wrong? If so, let me know I will be finishing the assembly over the holidays. Thanks

now I see, axle grease...that stuff looks nasty even when it is new

should be good then, my bad

The manual says

Place a small amount of high temperature grease on the actuator shaft lever.

. That might be a little overkill there

Is there a better type if grease to use? I have seen some type of white grease in some posts

speaking of overkill, how many of those teeth actually make contact when the actuator engages them...4 ?

haha yeah I see your point. I will take some off before assembly or the top and bottom end.

I used more grease then that when I put the KIPS back together on mine.

Yeah, Batesy, but you're not cheap like DIY and I

As for the grease, hi temp axle should be fine, just don't need that much. Remember that grease also attracts debris, so use just as much as you need. I have a tube of hi temp white lithium that says it's good to 600F, just dont remember where I got it from

bufftester wrote:Yeah, Batesy, but you're not cheap like DIY and I

I don't know if your at the level of DIY. You have a long way to go yet!

I have a gallon pail of Lubriplate or something like that and use a paint brush to glob it on stuff. What ever sticks should be good. And besides, that gear area is sealed from the inside and the out side so what ever you put in there should stay in and what ever is on the outside should stay on the outside.

rbates9 wrote:

bufftester wrote:Yeah, Batesy, but you're not cheap like DIY and I

I don't know if your at the level of DIY. You have a long way to go yet!
.

I am not that cheap, but as for the original poster, that is way too much grease there, go ahead an put it in a ziplock baggie and ship it to me