2005 KDX220 Top End

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OldRedd
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2005 KDX220 Top End

Post by OldRedd »

Hello, haven't been on this forum in a long time and feels good to be back. I ended up selling my 2006 KDX200 and have kept my 2005 KDX220R. Was considering getting a modernish bike as well, but have decided that since money is tight I am better off just freshening up the 220R. Since it still has the original top end from 2005, I figure I better replace it and have recently found out about the 220R stock pistons grenading. Luckily, in 16 years, I have not had a single problem with this bike and it gets ridden fairly regularly in the summer. in complete stock form Anyway, is there anything I need other than the Wiseco top end kit as well as top end gasket kit? Also, can I do it with basic tools as I have never replaced a 2 stroke top end? I am, however, fairly mechanical and have checked valve clearances on my old XR200 in the past and basic maintenance, etc. Lastly, I remember there used to be a digital KDX manual online somewhere but I can't seem to find it. Is the digital manual better than the book? Thanks for your input and glad to be back. :supz:
2005 KDX220-Completely stock
1998 XR200-Supertrapp Exhaust
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bufftester
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Re: 2005 KDX220 Top End

Post by bufftester »

The digital manual is the cyclepedia one. I use it more than my paper version and like it. Go to https://www.cyclepedia.com/ for more info. Top end job can be done with basic tools (really just need socket wrench and metric sockets 8, 12, 14 and a phillips screwdriver IIRC). A torque wrench for reassembly. The KIPS valve has a LHT fastener so the manual is good to have open. If you can do 4T valves you can replace a 2T tope end. And you don't even have to take the motor out of the frame for it.
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doakley
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Re: 2005 KDX220 Top End

Post by doakley »

In addition to the Wiesco kit you’ll need to order a new top end bearing, doesn’t come in the kit IIRC. I also prefer the online manual. This will be pretty easy for you.
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KDXGarage
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Re: 2005 KDX220 Top End

Post by KDXGarage »

YEP! Thanks for sticking with his, Mr. Recovery / doakley. The top end (small end) bearing is needed. Wiseco sells them.

Welcome back to the forums! Enjoy that KDX!
Thank you for participating on kdxrider.net. :bravo:
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OldRedd
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Re: 2005 KDX220 Top End

Post by OldRedd »

Yes!! I appreciate the input. I plan on ordering it all this weekend and starting into it next week. I love the 220. Lots of low end grunt and a wheelie machine. 15 years and going strong says something.
2005 KDX220-Completely stock
1998 XR200-Supertrapp Exhaust
pumpguy
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Re: 2005 KDX220 Top End

Post by pumpguy »

In addition usual mechanics hand tools, a 3/8" torque wrench is almost a must. The manuals give torque values for just about every fastener on the bike.

A Motion Pro # 08-0134 torque wrench adaptor is needed for the cylinder base nuts.

Also, be aware that some printed manuals have an error regarding assembling the KIPS sub valves.
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Re: 2005 KDX220 Top End

Post by KDXGarage »

Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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OldRedd
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Re: 2005 KDX220 Top End

Post by OldRedd »

Ah thanks for the heads up with regards to the torque wrenches. I need to get me some new ones.
2005 KDX220-Completely stock
1998 XR200-Supertrapp Exhaust
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