220 project on my garage

[Jodaddy]

Always wanted a kdx so here we go. I’m now the the 3rd owner. Surprisingly I know the guy who bought it off the showroom floor. What I’ve done so far: jetted the 35 mm carb which was swapped in at some point. 12 tooth front. Rebuilt rear MC. Brake pads front and rear. New air filter. Removed 2 shims from compression stack and heavier fork springs. New radiator cap and over flow bottle. Advanced timing to in between middle and advanced marks.
What’s on the list: new piston and pv clean, pegs(on the way), clutch pack and basket, shock rebuild, iridium spark plug, possibly kips spacer, possibly flywheel weight, bike has a pretty decent stocker pipe but I’ve been using a pretty heavily dented gnarly woods which I prefer so I’ll probably try to blow it out. Silencer repack. Clutch cable. Possibly air box lid. Possibly fancy clutch lever.
I’d really like to figure out a kickstand that doesn’t hang off the swing arm. Anyone tried the fastway for a kx125 or something similar?
If y’all see something I’m missing then please let me know.
Thanks. Joe

[Chuck78]

Welcome! The Gnarly Woods is an awesome pipe on a 220, but most people through second hand opinions will tell you it's not a good match for the 220.. I beg to differ, at first I really regretted losing the very smooth tractable torquey power of the Gnarly Woods pipe when switching back to the Pro Circuit and then Gnarly Desert then back to Pro Circuit pipes.... The PC may be my favorite, but the Gnarly Woods is the best for technical riding. The PC and Gnarly Desert are faster overall if you ride only fast race pace terrain, but when the terrain gets technical or if you just want an ultra smooth power delivery, the Gnarly Woods is definitely the best of all 3 aftermarket pipes and the OEM!

Wossner pistons are excellent, I recommend them over Wiseco every time for our bikes, unless you have a 223cc overbore 70mm cylinder, Wossner doesn't make one. They do make A, B, and C sized stock bore pistons, so have a shop with a dial bore gauge measure it for you. If they don't have the tools or know-how, take it to an automotive machine shop and ask if they can measure it for a small fee. Piston to wall clearance is a critical spec to not overlook... Wossner also come stock with coated skirts, which Wiseco does to some pistons, but not ours. Wossner having 69.00mm A-size, 69.01mm B-size, and 69.02mm C-size "stock bore" pistons as well as having coated skirts makes them the much bettr choice for longevity.

Wiseco only list a 69.00mm bore size piston nowadays for the 220... They also do not list A, B, and C sizings for the 66mm KDX200, BUT offer 66, 66.5, 67, 67.5, and 68.00 mm overbores for the 200 as if it came stock with a steel sleeve? Very odd that they'd skip the A, B, and C sizes. They should offer 66mm A, B, and C sizes, and a 67 or 68mm overbore specifically for the E-series as they cannot go more than 1 or 2mm oversized due to power valve location/design, and then the 69mm A, B, and C + 70mm
https://www.wiseco.com/product-category ... gL_JfD_BwE



as far as a kickstand, browse ebay photos of Yamaha YZ and YZ###F and WR### Trail Tech billet kickstands, these are the best to adapt to the KDX's. Most writeups on here and elsewhere have copied the first person to do this and used a 2003 KX/RM Trail Tech kickstand, including myself, but they take more modifying to work properly than the mid-late 2000's Yamaha Trail Tech versions. It's HIGHLY RECOMMENDED to weld on reinforcement to the frame on the chain roller tab, otherwise the flimsy chain roller tabs (NOT designed to hold up the weight of the bike + seated rider) will crack within a year or so... ask me how I know!!!! I might convert my 2nd 220 to bolt-on Yamaha footpeg mounts for better peg selection and better kickstand mounting while being able to still use the UFO or Hyde Racing frame protectors. Some of the later Yamaha Trail Tech kickstand brackets integrate the bolt-on left footpeg mount with the kickstand mount, which is brilliant but requires welding threaded sleeves into the KDX frame and grinding off the existing footpeg brackets. I'm relocating the upper shock mount anyways to run 96-08 RM125 rear shock / DRZ400 rear shock anyhow, might as well do more welding on the '99 220 frame!

[Chuck78]

Wossner is the way to go for KDX200/220 pistons. Wiseco sizes theirs as if they are a steel sleeved engine that gets overbored 0.50mm or 1.0mm with any hint of cylinder wear...

69mm A, B, and C sizes to match the honing size and wear on your plated cylinder...

https://wossnerpistons.com/collections/ ... ducts/8092




Vintco sells repackaged Wossners, but only list the A-size 68.94mm piston diameter. They sell new reproduction cranks though!
and they sell forged rods that I believe may also be made by Wossner, although they don't say Made In Germany like the pistons do, and the Vintco owners formerly were owners or higher ups at Pro Lite I believe? So they may be Wiseco/ProLite?
https://www.vintco.com/shop/Kawasaki/KDX220

[Jodaddy]

Welcome! The Gnarly Woods is an awesome pipe on a 220, but most people through second hand opinions will tell you it's not a good match for the 220.. I beg to differ, at first I really regretted losing the very smooth tractable torquey power of the Gnarly Woods pipe when switching back to the Pro Circuit and then Gnarly Desert then back to Pro Circuit pipes.... The PC may be my favorite, but the Gnarly Woods is the best for technical riding. The PC and Gnarly Desert are faster overall if you ride only fast race pace terrain, but when the terrain gets technical or if you just want an ultra smooth power delivery, the Gnarly Woods is definitely the best of all 3 aftermarket pipes and the OEM!

Wossner pistons are excellent, I recommend them over Wiseco every time for our bikes, unless you have a 223cc overbore 70mm cylinder, Wossner doesn't make one. They do make A, B, and C sized stock bore pistons, so have a shop with a dial bore gauge measure it for you. If they don't have the tools or know-how, take it to an automotive machine shop and ask if they can measure it for a small fee. Piston to wall clearance is a critical spec to not overlook... Wossner also come stock with coated skirts, which Wiseco does to some pistons, but not ours. Wossner having 69.00mm A-size, 69.01mm B-size, and 69.02mm C-size "stock bore" pistons as well as having coated skirts makes them the much bettr choice for longevity.

Wiseco only list a 69.00mm bore size piston nowadays for the 220... They also do not list A, B, and C sizings for the 66mm KDX200, BUT offer 66, 66.5, 67, 67.5, and 68.00 mm overbores for the 200 as if it came stock with a steel sleeve? Very odd that they'd skip the A, B, and C sizes. They should offer 66mm A, B, and C sizes, and a 67 or 68mm overbore specifically for the E-series as they cannot go more than 1 or 2mm oversized due to power valve location/design, and then the 69mm A, B, and C + 70mm
https://www.wiseco.com/product-category ... gL_JfD_BwE



as far as a kickstand, browse ebay photos of Yamaha YZ and YZ###F and WR### Trail Tech billet kickstands, these are the best to adapt to the KDX's. Most writeups on here and elsewhere have copied the first person to do this and used a 2003 KX/RM Trail Tech kickstand, including myself, but they take more modifying to work properly than the mid-late 2000's Yamaha Trail Tech versions. It's HIGHLY RECOMMENDED to weld on reinforcement to the frame on the chain roller tab, otherwise the flimsy chain roller tabs (NOT designed to hold up the weight of the bike + seated rider) will crack within a year or so... ask me how I know!!!! I might convert my 2nd 220 to bolt-on Yamaha footpeg mounts for better peg selection and better kickstand mounting while being able to still use the UFO or Hyde Racing frame protectors. Some of the later Yamaha Trail Tech kickstand brackets integrate the bolt-on left footpeg mount with the kickstand mount, which is brilliant but requires welding threaded sleeves into the KDX frame and grinding off the existing footpeg brackets. I'm relocating the upper shock mount anyways to run 96-08 RM125 rear shock / DRZ400 rear shock anyhow, might as well do more welding on the '99 220 frame!

Buddy of mine has a 06 125 that I can measure but I’m thinking those years would have the peg mount bracket install. Is that the trail tech stand you were referring to? Thanks. Joe

[Chuck78]

Steel frame YZ125 through '05, for the Trail Tech kickstand mount bracket fitment. It still requires some fab, but is the best I've found so far

[Jodaddy]

Steel frame YZ125 through '05, for the Trail Tech kickstand mount bracket fitment. It still requires some fab, but is the best I've found so far

Perfect. Thank you

[Chuck78]

Steel frame YZ125 through '05, for the Trail Tech kickstand mount bracket fitment. It still requires some fab, but is the best I've found so far

Perfect. Thank you

If you have access to a MIG welder, weld the mounting bolt holes shut, and then redrill them slightly lower to raise the bracket up, and front to rear drill the upper hole slightly further forward, & lower hole slightly rearward, to tilt the top of the bracket forward and bottom of the bracket rearward slightly. This work on this particular bracket is far less work than making the '03 KX/RM bracket work.

One of these days I might custom make a 95-06 KDX mounting bracket on my milling machine to sell, with as many people that want them.

[Jodaddy]

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last fall kdx adventure. Stock 220 and e series swapped RM. 220 went swimming that day requiring tank removal and upside down water extraction. Old girl fired up and continued on and got me back to the truck.

[KDXGarage]

Cool to get out there. Where were y'all riding, Endor? :-)