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New member with 2004 kdx220r

Posted: 10:54 am Oct 26 2020
by Bardo
I just got this bike. I have been looking for a clean kdx for awhile. I was wanting a 200 because of the piston problem on the 220r but it was such a clean bike i couldnt pass. I believe these are the original tires they say 2203 so i think they were made the 22nd week of 2003. The guy that owned it was original owner and thought there was less then 50 hours on it. He was an older retired gentlemen. Anyway 2 things i need to address first replacing the piston and second tuning the carb. The bike is running way rich and im sure it has the stock jets. I live at 4700’ i checked the air mixture screw and it was 1 turn out so i have some room to back it out. But i will probably need some different sizes. Where is a good place to get these? Would you guys go the JD jetting rout? Also for now i plan to keep it stock other then taking the snorkel out of the airbox lid.

The other thing i was wondering is if there was a really good tutorial on replacing the piston? I have replaced cylinder and pistons on a few chainsaws but never a bike. I saw how there were some things to look for like lefthand threads and things like that. I think i need a piston,rings, bearing and a gasket.

Thanks Brandon

Re: New member with 2004 kdx220r

Posted: 06:23 pm Oct 26 2020
by doakley
Welcome to the forums! Wow, that is a nice looking bike! Your very next purchase should be a good service manual. I like the Cyclepedia electronic version myself. It will answer all your questions about replacing the piston.

Re: New member with 2004 kdx220r

Posted: 08:30 pm Oct 26 2020
by bufftester
+1 on get a manual, and a torque wrench. Great looking bike.

Re: New member with 2004 kdx220r

Posted: 09:53 pm Oct 26 2020
by Bardo
doakley wrote: 06:23 pm Oct 26 2020 Welcome to the forums! Wow, that is a nice looking bike! Your very next purchase should be a good service manual. I like the Cyclepedia electronic version myself. It will answer all your questions about replacing the piston.
I saw that one and had it in my ebay cart. Is it an actual paper manual? I dont want one i have to look at a screen.

Brandon

Re: New member with 2004 kdx220r

Posted: 11:34 pm Oct 26 2020
by KDXGarage
Welcome to kdxrider.net. Nice bike!

"top end gasket kit" is what you need. Cometic is a good brand to check out.

Look into getting new tires and tubes, as those tires will not be too flexible, as they are indeed from the 22nd week of 2003 (17 years old). You wouldn't run 17 year old tires on a car would you? :-)

Re: New member with 2004 kdx220r

Posted: 09:52 am Oct 27 2020
by TwistedRoot
Congrats on the bike. I cant imagine a better place to own a dirt bike than SW Utah. I lived in St George for a few years, what a great town.

Re: New member with 2004 kdx220r

Posted: 10:47 am Oct 27 2020
by MoonStomper
Smoking hot bike! Man, to have that bike AND live in Utah? You're going to have some fun!

Re: New member with 2004 kdx220r

Posted: 12:12 pm Oct 27 2020
by doakley
The Cyclepedia manual is available printed or online. I have both but prefer the online version. I use an iPad in the shop and like how I can zoom in on the photos for clarity.
+1 on the torque wrench too.

Re: New member with 2004 kdx220r

Posted: 10:03 pm Oct 27 2020
by Bardo
I will get one of those manuals. I like St George born and raised here. Grew up ridding 2 strokes in the dessert in the early 90’s but havent done much ridding in years. Seems the kdx will be a great bike for trails. Need to get the jetting dialed. Probably will need to change it depending where im at -anywhere from 2,500’-10,000’ And 110 degrees to below freezing. But will be doing most my ridding at around 5,000’

Brandon

Re: New member with 2004 kdx220r

Posted: 07:16 am Oct 28 2020
by oldmankdx69
Very nice looking mc. +1 on service manual. Doesn't matter which one, just get one. Lot's of good info on this forum, all you have to do is search. Good luck and have fun!!! :supz:

Re: New member with 2004 kdx220r

Posted: 10:13 pm Oct 29 2020
by Bardo
Got the shop manual, a piston, bearing and gaskets ordered yesterday. Should be here early next week. Tweaked the jetting it had a 42 pilot, 138 main and the clip was in the 3rd position on the needle. I thought the main seemed lean. Went to a 40 pilot 142 main and second slot on the needle.

Re: New member with 2004 kdx220r

Posted: 11:49 pm Oct 30 2020
by KDXGarage
WOW! 138 main

Re: New member with 2004 kdx220r

Posted: 02:59 pm Nov 01 2020
by javjacob
The 220 with a FMF Gnarly desert/rev pipe, RB carb and head mods and a Wiseco piston is as good as it gets for a woods bike.

Re: New member with 2004 kdx220r

Posted: 05:00 pm Nov 01 2020
by doakley
javjacob wrote: 02:59 pm Nov 01 2020 The 220 with a FMF Gnarly desert/rev pipe, RB carb and head mods and a Wiseco piston is as good as it gets for a woods bike.
Yup!!

Re: New member with 2004 kdx220r

Posted: 01:17 am Nov 02 2020
by Bardo
How are the lectron carbs? I went on a 38 mile ride started at my house at 4700’ went up to 6900’ then 3100’ the biggest drop was 1100’ in 1.5 miles. Probably wont go much lower maybe 2700’ but Could easily go higher. Seems several people have problems with them fitting. Dont want to spend $500 and it not fit. Might put the desert pipe on it what reeds go good with the lectron?

Thanks, Brandon

Re: New member with 2004 kdx220r

Posted: 11:26 pm Nov 21 2020
by Bardo
Finished the top end. The old piston was in good shape but now i dont have to wonder. Seems to have more power down low but i did put in some boyesen 607 reeds. Had to go to a 38 pilot jet. Put 2 hours on it. The old piston had 125psi at 4700’ havent tested the new one yet.

Any one use the lectron carbs? Found some threads from 2017/2018 seems people were having issues with them fitting. Are those issues worked out. Is it worth the money? I am thinking about one to deal with elevation changes.

Brandon

Re: New member with 2004 kdx220r

Posted: 12:56 am Nov 22 2020
by KDXGarage
Hi. Read some of the threads from 2020. I think they altered it a little to fit KDX's or something like that.

Re: New member with 2004 kdx220r

Posted: 08:46 am Nov 23 2020
by MoonStomper
Bardo wrote: 11:26 pm Nov 21 2020 Finished the top end. The old piston was in good shape but now i dont have to wonder. Seems to have more power down low but i did put in some boyesen 607 reeds. Had to go to a 38 pilot jet. Put 2 hours on it. The old piston had 125psi at 4700’ havent tested the new one yet.

Any one use the lectron carbs? Found some threads from 2017/2018 seems people were having issues with them fitting. Are those issues worked out. Is it worth the money? I am thinking about one to deal with elevation changes.

Brandon
Would love to see your compression test of the new piston.

Re: New member with 2004 kdx220r

Posted: 08:39 am Dec 11 2020
by Bardo
Well the bike has about 5 hours on the new top end. I tested the compression and got 138 (thats at 4700’) that would be about 154 at sea level. I did all the compression testing on a cold engine. I just pulled the head off and sent it to RB.

Brandon

Re: New member with 2004 kdx220r

Posted: 01:22 pm Dec 11 2020
by decluk13
I don't have time or patience for swapping jets. I put a Lectron on my bike this spring and it hasn't needed adjustment yet. They have a cutaway thats standard on the KDX model to correct previous fitment issues. Choke on the wrong side is my only gripe but you could always get the remote choke.