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Does anyone know of a better set of brake pads and/or caliper that can be used with the stock caliper and forks? I currently have the original pads on the front and it definitely leaves something to be desired with brake power. I’m pretty sure I could not do a stoppee.

May I ask how old the brake fluid is?

The OEM front brake is spongy, Stainless line takes care of most of it, new fluid and a master cylinder rebuild with new pads will get the rest

Even new, it was not a super strong brake system, however. Fresh fluid can help some.

Check your disc rotor for thickness & uneven wear as this can effect stopping power....I had a similar problem on my 220 , but after fitting a new & slightly thicker aftermarket wavey rotor from a kxf 250 the stopping power has improved with a more solid feel to the leaver.

Which year and model is this??

Ever change the fluid or seals?

I have been wondering the same thing. I didnt do a caliper rebuild but I flushed the old fluid. I have new brake pads and my rotor is within spec. I will prob get a stainless line. Have heard they help a bit.

Where do you buy the stainless line?

https://www.coremoto.com/

(From eric_r rebuild thread)

viewtopic.php?f=77&t=22266 . See page 5.

I apologize for not giving bike specs. It's an 02 220. I'm going to assume it has the original brake fluid in it. I think it spent most of it's time in the garage. The brake fluid looks good in the sight glass but that doesn't mean it's good. As far as the rotor I'm going to say it is within spec as the bike I believe had less than 10 hours on it. The lever is pretty solid and didn't give me any reason to think it was not good. But with anything pushing 20 years old it should be looked at. Bleeding brakes makes me want find something else to do for fun.

If the brake fluid has never been changed, then it is 19 years old. I suggest you do a complete flush. I am pretty sure it won't hurt.

Yes that’s on my to do list, that and change the pads.

So, cornishwrecker220 mentions replacing the rotor with a KX250F rotor. Are the KX250F or other KX rotors compatible with KDX and if so what years? I have a 2004 KDX 220 with stock forks, etc. and am looking for a new front rotor and wanted a more cost effective replacement. I have read that the bolt holes line up but are 5mm vs 6mm and would have to be drilled out. Seems easy to do in the garage but like I said @ ~ $105/per I'd like another option if possible.

Look in the EBC catalog to see what matches up. Some Kawasaki models will interchange.

dennis kirk for fitment also

Thank you. So far it's looking like I'm stuck with two ebc models specific to the kdx. I've reached out to FRP for suggestions as well. They've helped me with fork springs previously and were great. Cheers

I gave you a signature. I saw where halfway through the thread you mentioned it, but that was no help now at the bottom or in the future.

if you are OK with Chinese rotors, there are several on eBay.

I thought RM would have had a Tusk.

It looks like it is:

1995 - 2006 KDX200
1997 - 2005 KDX220R
1991 KDX250