Newb - 03' KDX 200 rebuild help

[sangle333]

I know there's tons of threads talking about rebuilding the top end etc. but, I'm a total newb on 2T.

Why an I rebuilding? Well just bought it earlier this year and with your help I fixed the leaking pipe from the engine and found a stock air box. Overall the bike runs good although the engine is loud like the piston is slapping. The guy I bought it from raced for 2 years on it. He said he looked at the piston and it looked fine but, after 2 years of beating on it I'm guessing I should replace the piston in hopes the slapping goes away.

I've read Wiseco is preferred. Do I buy the kit or just the piston?

Is there a step by step video or thread on how to rebuild the top end?
- Do I need to take the engine off the frame to do this?
- I read about the 'left' threaded bolts. Check
- And to support the shaft when removing the nut. What do you use to support it? Anything that will fit?

Thanks in advance!

[KDXGarage]

kit and small end bearing

piston
rings
two circlips
pin
small end bearing
gasket kit
fresh coolant

do not need to take engine out

Left Hand threaded bolt and nut is the KIPS advance shaft

Yes. DO SUPPORT it when turning. flat wrench, adjustable wrench, etc.

[sangle333]

kit and small end bearing

piston
rings
two circlips
pin
small end bearing
gasket kit
fresh coolant

do not need to take engine out

Left Hand threaded bolt and nut is the KIPS advance shaft

Yes. DO SUPPORT it when turning. flat wrench, adjustable wrench, etc.

https://www.powersportsdiscount.com/product/42124
Thanks Garage - Is the above link what I should purchase?

[Molly's 70]

That's the right kit. Sometimes it's just a generic picture to fit all.

[sangle333]

That's the right kit. Sometimes it's just a generic picture to fit all.

Seems like a decent deal too. Purchased!

[doakley]

kit and small end bearing

piston
rings
two circlips
pin
small end bearing
gasket kit
fresh coolant

do not need to take engine out

Left Hand threaded bolt and nut is the KIPS advance shaft

Yes. DO SUPPORT it when turning. flat wrench, adjustable wrench, etc.

https://www.powersportsdiscount.com/product/42124
Thanks Garage - Is the above link what I should purchase?

Service Manual!

[KDXGarage]

I agree!

manuals.JPG (73.57 KiB) Viewed 1971 times

[sangle333]

Yes, yes...finally bought one because of this. Ugh! Thanks for you help!!

[KDXGarage]

The beatings will continue until morale improves.

[pumpguy]

The beatings will continue until morale improves.

I LIKE THAT!