2020 KDX 220 project restore

[treedodger]

Hey all. I just finished up my winter long refresh on my 03 KDX 220R and wanted to share the results. A bit of a story on this ole bike... I bought it in 2011 in nearly new condition off a guy that only put 30 miles total on it. I was going through a personal rough spell, and this bike in 2011 was my medicine.

You can see my old post for first time build, but basically all(most) of the fun stuff a 220 likes.

Fast forward. I rode the hell out of it for about 3 years and parked it. It sat. Then.. my 14 year old son... who out grew his kx85.. took an interest in my old girl. He started riding, then every day riding. His personal skills were climbing faster than on any bike he’s ever had.

Then.. he started racing it! He did more than a handful of southern series hair scrambles and such. He finished every race, which given the wet conditions is kind of amazing. Even got a few top 5 in his class on the old KDX.

Well, as it turns out.. old bikes, racing and teenagers isn’t a good mix from a machines point of view. As my bob said, “this bike is clapped out”. What ever the hell that means. He even said “no way that bike will ever ride like new again”. That part I understood and took as a personal challenge.

Enter 2020 KDX 220r redo...

Here is the buy list best I can recall. I took the old girl down to frame and built back up, replacing one “clapped” part at a time.

I want to give a shout out to Kawasaki parts warehouse. Seriously. E-V-E-R-Y single part on this old bike is for sale. Old rubber side plate rubber stopper? No problem. And so on.

Motor——
-fresh wiseco top end
-new water pump
-new clutch
-refreshed clutch basket
-new water hoses
-new air filter
-new carb cable/misc carb rebuild stuff
-new fuel and over flow tubes/blue
-new plug/ignition wires and boot
-heat/header paint the jug blue
-sand/paint all mounts/brackets/misc parts
-sandblasted bolts

Suspension-
-local race tech, tech rebuild. F/R
-new springs F/R several sizes up on both

Chassis—-
-sand/paint frame, swing arm, everything
-new swing arm bearings
-new suspension pivot bearings
-new wheel bearings
-new suspension triangle arm replace (out of tolerance)
-new brakes, caliper rebuilt
-new fork boots
-new handle bar rubber mounts
-new head light
-new pegs
-new pipe hanger brackets.
-new front rim
-new f/r tires
-new pet cock
-new renthal sprocket
-new rk chain
-bunch of misc frame rubber mounts and such.
-new grips
-replace tree guards
-new mud flap

Bling—-
-new rear plastic mx straight
-new front plastic from 2019 kx250f
-new pro taper clutch levers
-new motocal custom graphics (I personally designed those in their app)
-new seat foam
-new seat cover
-boyseen ignition cover (it just looks too nice not to buy)
-new clear sticker for forks/frame
-skate board deck tape.. for heavy rub area on frame
-gas cap vent thingie
-devol radiator guards
-devol rear caliper guard


I’m sure I’m forgetting something.

My kid, and all his riding buddies have given the project a thumbs up— and my biggest reward was when my kid said “well, I guess you can make an old bike new again”.

The real question is if I let him ride it again!!

One before pic —the rest after the restore

[KDXGarage]

WOW! Wonderful job! I like your color choices. Congratulations and even THANKS! on getting it back to a wonderful state.

[Molly's 70]

Cool tuff! I like it!

[treedodger]

A few more pics

[lizardfungus200]

Awesome dude. I like the blue. Are you selling your stator coils perhaps?

[treedodger]

I found eBay to sometimes be the “only” source for some parts. Here’s a stator reasonable price.

https://www.ebay.com/itm/Stator-for-Kaw ... Sw-K9ZFhY4

[bufftester]

As a PNWer like the Seahawks color scheme That pipe needs a little love tho....

[RedstoneDC]

That's a great looking bike. I just acquired a 220r and started going thru it. It is going to take a while before it looks half as good as yours!

[NewfieBullet69]

Looks good! What did you do to paint the frame and swingarm? I'm in the process of restoring my old girl and I haven't got a clue when it comes to painting. What type of primer, paint and clear coat should be used to stand up to gas spills and dirt bike wear? Of course, no paint job will be the same as powder coating, but I'd rather spend what it would cost to powder coat in performance rather than aesthetics.

[javjacob]

That looks really good. I also like how you kept the bag with the MX rear fender.

[javjacob]

I did a full rebuild on my 220 in 2017 and I did a full rebuild on my 200 that I just finished a month ago. I went through everything and made them like new again. These bikes are more than worth fixing up. I would take a fixed up 95-06 KDX over any new bike made anyway. Both mine have the RB carb and head mods, FMF rev pipes, turbincore2 silencers and KX fork swaps done.

[treedodger]

Looks good! What did you do to paint the frame and swingarm? I'm in the process of restoring my old girl and I haven't got a clue when it comes to painting. What type of primer, paint and clear coat should be used to stand up to gas spills and dirt bike wear? Of course, no paint job will be the same as powder coating, but I'd rather spend what it would cost to powder coat in performance rather than aesthetics.

There is another quality frame up restore post here were I think he uses a much better painting solution. I’d call my paint job best of low end.

On frame.. you can find Kawasaki green rattle can on amazon. I sanded, degreased, and rattled frame.

On head- I used vht paint.. that ford blue is a great match for Kawi. It’s high temp too. Same prep process

On other silver parts..vht also makes metallic aluminum paint. Same prep, and it’s a dead match for forks, swing arm, kick stand, motor parts etc. so far it’s held up ok. I did wrap fork lowers with clear vinyl thick stickers to protect a bit.

Yes, much better way to paint. I’m pretty happy though for money and time spent.

[VTMTcowboy]

Great job on the restore! I like the blue green combo a lot.

How do you like those pegs and how was the fitment? I saw them on Amazon/eBay and was curious about them. I like the green anodized look but I was a bit hesitant due to the country of origin. Thanks!

[treedodger]

Great job on the restore! I like the blue green combo a lot.

How do you like those pegs and how was the fitment? I saw them on Amazon/eBay and was curious about them. I like the green anodized look but I was a bit hesitant due to the country of origin. Thanks!

I actually haven’t put ride time on this winter project because it’s been so wet here on east coast. Those pegs are the only china junk on this build. They fit ok no problem, and look just ok. The green doesn’t match any other green. Should have gotten black. They look like they might break honestly.

As a side note... as a guy that just bought a bunch of bike stuff.. it’s getting harder to find non-China parts. Amazon is almost a no buy zone, and places like Rocky Mountain atv aren’t much better. If you’re searching for just quality brands (I.e “pro taper” not just clutch levers) you might have better luck. It’s seems like eBay had biggest options for non-China stuff, as did Kawasaki parts warehouse.. just KPW was only oem and the most expensive.

[KDXGarage]

treedodger, have you never heard of IMS footpegs?

Is there a model of Pro Taper bars that is not made in China?

Which items did you look for that there was no part not made in China?

[treedodger]

treedodger, have you never heard of IMS footpegs?

Is there a model of Pro Taper bars that is not made in China?

Which items did you look for that there was no part not made in China?

Amazon is the worst I think. If you’re just searching generic stuff, say “kx shifter” or “kx levers” or any basic/semi-generic part- the first option they offer is typically junk. Even if you flip through pages and pages, you might never get presented a quality part unless you search “ims pegs” or “pro taper levers”.

And even though I prefer quality, Sometimes the junk just looks tempting and I make poor choices.

[javjacob]

Ebay and Amazon are nothing but cheap China junk rip offs. I only use Ebay if Im searching for discontinued or used OEM parts

[javjacob]

And even though I prefer quality, Sometimes the junk just looks tempting and I make poor choices.
[/quote]

I never buy China parts even if it looks good and is 1/10th the price. I refuse to support these poor quality manufactures that are only hurting the manufacturers that actually make quality parts. I also hate supporting China, a country that does nothing but rip everyone off. If everybody refused to buy China junk we wouldn't have to deal with all the poor quality throwaway junk we have accepted as normal.

[VTMTcowboy]

Great job on the restore! I like the blue green combo a lot.

How do you like those pegs and how was the fitment? I saw them on Amazon/eBay and was curious about them. I like the green anodized look but I was a bit hesitant due to the country of origin. Thanks!

I actually haven’t put ride time on this winter project because it’s been so wet here on east coast. Those pegs are the only china junk on this build. They fit ok no problem, and look just ok. The green doesn’t match any other green. Should have gotten black. They look like they might break honestly.

As a side note... as a guy that just bought a bunch of bike stuff.. it’s getting harder to find non-China parts. Amazon is almost a no buy zone, and places like Rocky Mountain atv aren’t much better. If you’re searching for just quality brands (I.e “pro taper” not just clutch levers) you might have better luck. It’s seems like eBay had biggest options for non-China stuff, as did Kawasaki parts warehouse.. just KPW was only oem and the most expensive.

For sure it has been and is the direction we are going in. I was solely curious about the fitment and quality. I definitely didn't want to start a firestorm thread about part production and quality... those discussions are meant for other forums where you get attacked for asking a simple question.

I know IMS kind of leads the foot peg market for older bikes. I have a set of Pro Series but I do like the anodized look and the price point. But I guess the old adage of "you get what you pay for" rings true here. Definitely keep us updated on a "long term" report. Thanks mate and once again, beautiful resto!

[KDXGarage]

Yeah, I'm just saying there are alternatives out there.

I am slow as sh** in the woods, but I am a AA Pro internet shopper for parts.