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We've all heard the horror stories, and seen the recommendations, and I'll add my experience to the list. I have owned my 220 since it was brand new in 2001. Spent a lot of time in the Florida panhandle woods the first few years. Then 4 years in North Dakota where the riding season is short, and the last 11 years in the Pacific Northwest. Probably around 4500 hours on it between it's original form and the hybrid it is now. I never heeded the advice because honestly I'm cheap and would rather ride than wrench, and always figured if it did blow up then it was a sign to get a new bike lol. So about 8 miles out into the woods it meet it's demise. It wasn't a bad event, the bike just lost power on a climb and turned over but wouldn't start. Pulled the plug which was very wet, thought "huh, that's odd", and put a new plug in. Fired right up and made a sound no body ever wants to hear out of their bike so shut it down. Conferred with my riding partner (son) who said something smart mouthed like "guess you should have taken you own advice" or some such rubbish and we found out way out to the nearest FS road where we employed the tow strap (I do take some of my own advice ) and we made it back to the truck for the drive of shame home. Initial pics below hurt to look at. The financial advisor (wife) was quick to affirm that it was repairable and there would NOT be a new XC\W under the Christmas tree lol. Of course now I have a good excuse to do some tear down pics on the way to a fresh motor. It will be getting new bearings and seals throughout, as well as the wiseco and possibly a replate. Initial look send like most of the skirt went to the bottom end and not a lot of damage to the head or cylinder.

More, looks like a replate is in order

And more. Piston doesn't look too bad for the hours on it.

SEE!! Only got 20 years and 4,500 hours on it! REPLACE IT IMMEDIATELY!! :-)

ANYONE that buys a used KDX of any engine size should check EVERYTHING thoroughly. The 2022's of various models are out on the trail, so that makes about 16 years since the last KDX version was released.

Man, you were lucky! You ended up with almost zero damage. You're also lucky in that a stock 220 piston lasted that long. Should have replaced it at least 2000 hours ago!

With all the good advice you give on here I would've put money on it that your 220 didn't still have the stock piston. I imagine that engine sounded like 3rd Gens engine clacking away. I'm sorry to hear your day was cut short and now you have your work cut out for you. I'm looking forward to seeing the rebuild progress.

Yeah, my wife tells me all the time I am much better at giving advice than taking it lol. Actually, right up until it let go my bike had very little "KIPS Rattle" sound and a few months ago still registered 125psi for compression. I had thought about doing it many times over the years, but the bike has given me almost no problems over its 20+ year lifespan. My brother-in-laws 2019 KTM is on its 3rd piston due to TPI issues.

Wait, is that legitimately the OEM "factory" piston that was in the bike when it was manufactured 20 years ago?

Now I’m wondering what percentage of bikes even get 2000 hours out of their factory pistons? You say you don’t like to wrench… Did you ever do the rings?

MoonStomper, it's not a Honda Civic. :-)

Few more pics from tear down. Carbon build up not too bad, plenty of lubrication present lol. Cleaned up now and what initially looked like damage was just carbon and debris from the skirt. Actually looks pretty good, given it's she it'll still get a replate for good measure.

Finally got around to splitting the cases today. The good news in all this is that my cylinder suffered no damage. Off course that means there is bad news, and it is that I am now shopping for new case halves. Going to have a welding shop that specializes in engine work take a look, but I fear it may be unsalvageable.[album][/album]

Ouch! Is that damage from the piston coming apart?

Oopsies.

Check the cylinder for egg shaped wear also.

That can be welded.

SS109 wrote: 09:03 pm Oct 24 2021 Ouch! Is that damage from the piston coming apart?

Yes, looks as if the skirt came apart in big pieces that were then used to jackhammer the internal baffle between the bottom end and the transmission. If it can be welded that will be a minor miracle.

bufftester wrote: 03:18 pm Oct 25 2021Yes, looks as if the skirt came apart in big pieces that were then used to jackhammer the internal baffle between the bottom end and the transmission. If it can be welded that will be a minor miracle.

This is why you can't trust a cast piston in the 220. Most people get pretty lucky. Sadly, you did not.

You can't let a piston run that long, unless maybe you are following the great grand children around.

True, though I was lucky for 20 years and 4500 hours And even chasing the grandkids it's probably not a good idea lol

:-)

GREAT grandkids (even slower moving children)