Resurrecting KDX 220

[FLBoyKDX220]

Hey guys, another old dude refusing to get old here lol. Im 47, started riding dirt bikes again after a 30 yr break for kids and life stuff. Bought an XR650L 3 yrs ago and have thoroughly enjoyed it but it is more than a handful on single track. Ive tried straightening the curves more than once and almost pulling my elbows out of socket holding on when it got loose haha. Ive been researching for a smaller woods bike and the KDX seems pretty awesome. SO here I am. Picked up a 2003 KDX 220 for $900. It ran but barely. Im in the process of getting the critical stuff done but it needs pretty much everything as its well worn. It was running super rich and I see why now. The foam air cleaner was like chewing gum, exhaust O rings were blown out, clutch toast, kickstarter gear or spring issue, front fork seals blown, rear shock blown, rear brakes seized and Im sure every seal or bearing needs to be replaced. Getting the clutch back in now so hope to at least ride it around the block before I commit to the fork & shock rebuild. EDIT SNIP (Please leave kdxrider.net out of the copyright infringing manual sites and links. Thank you.)

Much appreciative for all the great posts that have helped me over the last few weeks working on my KDX. Thanks guys! Hope to hit some hare scrambles this season.

[BlkDakDave]

Welcome to the KDX legion of resurrection. I just picked up a 2004 220 that needs a little work. Sounds like you have a good project bike and an opportunity to make that bike yours. Yes, the KDX will feel like nothing compared to the big thumper. Don't get me wrong, those big thumpers have their place. Whatever you do, don't sell it as it could be hard to replace. Keep us updated on your progress.

[FLBoyKDX220]

Thanks BlkDakDave. That was my thoughts of it being mine since it needs so much. Hopefully the "needs" wont blow the budget as Im sure the "wants" will. Will keep the XR for sure, It WONT be one I say years later I wish I still had. Look forward to putting some 50/50 tires on it now that Ill have the KDX up & running soon. Ive always been a Honda guy but couldn't pull the trigger on a CR250 or a CRF450.

[bufftester]

Welcome to the forums and congrats on the new bike. Top of your list should also include a new piston, the 220 OEM ones are time bombs, plenty of info available on them here. Pay particular attention to your linkage and swingarm bearings, they get overlooked a lot and are some of the most abused spots on the bike. Fork and shock rebuilds are easily done, in fact there really are very few things a home shop can't do on a KDX. It even still has the odometer cable, though I've never seen anyone mount the light switch in that location before. And don't forget fork boots after you rebuild those forks, they will help those seals last much longer.

[FLBoyKDX220]

Thanks bufftester, sounds like good advice on the piston. A kid owned it and Im having a hard time telling what is stock KDX and what he goofed up. Some bolts are mismatched and various stuff missing.

[kdxsully]

All good advice here. I was gonna say you got it for a steal at 900, but after reading I’d say “fair.” Good luck with the rebuild and focus on the light at the end of the tunnel!

[bufftester]

Its a steal compared to prices here in the Pacific NW, seen rougher ones than that go for twice as much. If I could find another H or 220 under 1k I'd buy it in a heartbeat. Fixing PO repairs is always a fun act of discovery!

[FLBoyKDX220]

Florida prices are on the higher side so Ill probably wind up having what Its worth in it as long as I can do all the work myself. Good running condition brings $1,800-$2,200. Its fun tinkering on it. At least Ill know what Ive got and how to fix it if it ever breaks.

[KDXGarage]

Welcome to the forums. You may want to check the year, as purple tank and green frame is a few years earlier.

Please don't provide links or sites to copyright infringing manuals on kdxrider.net. This site wants no part of the legal concerns.

[FLBoyKDX220]

Understood, only had good intentions providing that for newbies but I get it.

This purchase keeps getting more interesting. I never bothered looking up the VIN but but just checked and the 10th digit is a V. Looks like that is a 1997 A4 model?. Oh well at least I got a KDX. Wondered why other 2003 models looked different.

[kdxsully]

Understood, only had good intentions providing that for newbies but I get it.

This purchase keeps getting more interesting. I never bothered looking up the VIN but but just checked and the 10th digit is a V. Looks like that is a 1997 A4 model?. Oh well at least I got a KDX. Wondered why other 2003 models looked different.

They’re fundamentally the same throughout the years, I believe.

Check the VIN and the engine serial. Make sure your motor is the right year too.

[javjacob]

Very nice! 95-06 are all the same except for different colors and decals. 1995 through I believe 2002 had the green frame. I think it was 2003-2006 that had the silver frame. I personally like the green frame much better.

[FLBoyKDX220]

Unfortunately this bike is a country song. It was an out of town buy that a riding buddy checked out and picked up for me. I did manage to get it cleaned up & running well but found a glob of JB weld on bottom of the crankcase dripping oil. Never could have seen it thru the grime. Was sure hoping it was just seals but nope. So... I just don't have the time for this kind of project. Ill be selling for parts. Ive got $1,200 in it. New clutch & cable, tires, exhaust o rings, chain & front sprocket, foam air filter.

[kdxsully]

Unfortunately this bike is a country song. It was an out of town buy that a riding buddy checked out and picked up for me. I did manage to get it cleaned up & running well but found a glob of JB weld on bottom of the crankcase dripping oil. Never could have seen it thru the grime. Was sure hoping it was just seals but nope. So... I just don't have the time for this kind of project. Ill be selling for parts. Ive got $1,200 in it. New clutch & cable, tires, exhaust o rings, chain & front sprocket, foam air filter.

That’s a shame. There’s always this kind of risk in buying used bikes

[javjacob]

That's a shame you are parting it out. You could find a case to replace the broken ones or have a good welder fix it right. Then you can do new crank seals and top end and know what you have. Just hate to see these bikes get parted out. If you do let me know what you want for the rear wheel if its in good condition.

[FLBoyKDX220]

I should rephrase that. Im going to sell it as a complete bike, not parting it out. To someone skilled enough it is definitely worth salvaging. Otherwise there is a ton of good parts on it as a whole. It has a busted case, kick starter skips, both forks & rear shock need rebuild.

[KDXGarage]

Sorry to hear of it!