PSA: don’t skimp on top ends!!

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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Mnolan660r
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PSA: don’t skimp on top ends!!

Post by Mnolan660r »

Hey all!
Just a PSA, check those top ends!!

Had a buddy bring me his 220 for a complete re-seal/ new bearings/ top end etc.
His bike has had the Fredette porting done, and RB carb and head mods done.
Initially he brought it over due to having issues tuning, and finding “oil” in the stator area. ( main seal bad)

Needless to say, I was a bit surprised when I pulled the jug off of the lower end. He was told by the PO that he had “just done the top end”. 🤦‍♂️ He has only put maybe 6-8 hours on the bike since he got it.

Found a pretty big spot where the plating failed, and needless to say, the piston is done!

His jug was also cracked in the same spot that my 200 was, but way worse. Unsure if this is a result from the material removed when the porting was done, or what. He’s currently looking for a replacement jug.
Almost afraid to pull MY 220 apart, but need to know!!! 😅
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SS109
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Re: PSA: don’t skimp on top ends!!

Post by SS109 »

Cylinder can be saved. I had a crack in my 220's cylinder and Millennium welded it up and replated it.
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Re: PSA: don’t skimp on top ends!!

Post by KDXGarage »

DAMN

Do read up on their welding and repair options.
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