2002 KDX220R Rebuild

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: 2002 KDX220R Rebuild

Post by Slick_Nick »

TheYakk220r wrote: 04:24 pm Apr 10 2021 harvester, the swingarm paint is on of the duplicolor silvers with primer coats and clearcoats.

Nick, thanks for the heads-up. Hopefully that was just a bad batch you got.
I wish it was, but I used the clear again on a smallblock chevy I built for a guy, and the same thing. Turned "nicotine yellow" after the first few times it was up to temp. Never again will I use that clear.

Stick to a base color and it seems to be fine. As soon as you add clear, either on top of a color or just by itself, it yellows pretty bad.
'00 KDX 220R
TheYakk220r
Member
Posts: 51
Joined: 11:05 pm Jan 06 2021
Country: Colorado USA

Re: 2002 KDX220R Rebuild

Post by TheYakk220r »

Got a few more parts on. New tires and tubes front and back, tire wrestling. Making use of the old rims for now until the next upgrade session. Cleaned up the used aftermarket front fender, reshaped back to new with heat gun, sanding and scraping and some SC1. Looks pretty good. New Maier rear fender color is very close match.
88.jpg
88.jpg (596.88 KiB) Viewed 5444 times

The old tank is in a bit rough shape. Sanding and scraping and SC1. Looks acceptable for now.
89.jpg
89.jpg (328.29 KiB) Viewed 5444 times
90.jpg
90.jpg (461.79 KiB) Viewed 5444 times
91.jpg
91.jpg (428.91 KiB) Viewed 5444 times
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 2002 KDX220R Rebuild

Post by KDXGarage »

Looking good! Come do mine. LOL!
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
Bauer9168
Member
Posts: 9
Joined: 02:52 am Sep 15 2019
Country: USA

Re: 2002 KDX220R Rebuild

Post by Bauer9168 »

Can you show or describe the process in getting the tank /plastics looking nice again? Not sure what sc1 is.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 2002 KDX220R Rebuild

Post by KDXGarage »

Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
TheYakk220r
Member
Posts: 51
Joined: 11:05 pm Jan 06 2021
Country: Colorado USA

Re: 2002 KDX220R Rebuild

Post by TheYakk220r »

Here is a good video description of restoring plastics.

stnd
Supporting Member I
Supporting Member I
Posts: 24
Joined: 08:48 pm Apr 15 2018
Country: Canada
Location: Toronto

Re: 2002 KDX220R Rebuild

Post by stnd »

Another product i use on my bikes and other plastics to give them a new shine (wont repair just maintain) is Plexus Plastic Cleaner. I source it locally and don't think it's worth the price in the link.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 2002 KDX220R Rebuild

Post by KDXGarage »

look on Youtube for the video of the guy restoring a red plastic fuel tank

time, money and effort will get some ver good results and much cheaper than paying a rapist for a new fuel takn (oops, eBay seller with a NOS part).
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
billie_morini
Gold Member
Gold Member
Posts: 187
Joined: 04:31 pm Aug 02 2020
Country: Central Coast California

Re: 2002 KDX220R Rebuild

Post by billie_morini »

Lotta love and good work going on from The Yakk!
TheYakk220r
Member
Posts: 51
Joined: 11:05 pm Jan 06 2021
Country: Colorado USA

Re: 2002 KDX220R Rebuild

Post by TheYakk220r »

Thanks for the comments.

Did a little rework on the skid plate to make sure the pipe fits with clearance on both sides. Pipe installed with new rings, exhaust springs, and high-temp silicone.
92.jpg
92.jpg (453.26 KiB) Viewed 5291 times

Went ahead with the FS approved spark arrestor muffler so all legitimate to ride in the woods and grasslands.
93.jpg
93.jpg (473.85 KiB) Viewed 5291 times

New seat cover turned out pretty good and much better feeling than the old slick one.
94.jpg
94.jpg (541.85 KiB) Viewed 5291 times

Pretty close now. Installed the cleaned-up side panels front and back, same graphics I had. Waiting on the brake bleeder vacuum and new air filter. Need to put in fresh fluids and go through the piston break-in process next.
95.jpg
95.jpg (518 KiB) Viewed 5291 times
96.jpg
96.jpg (1.61 MiB) Viewed 5291 times
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 2002 KDX220R Rebuild

Post by KDXGarage »

Where is the other KDX for riding that is to accompany this "for display purposes only" KDX? :partyman:
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
TheYakk220r
Member
Posts: 51
Joined: 11:05 pm Jan 06 2021
Country: Colorado USA

Re: 2002 KDX220R Rebuild

Post by TheYakk220r »

I wish there was another one but they are getting a bit hard to find in this area. Besides, dirt bike has the word dirt in it, so it will be getting dirty for sure. I'm happy to be getting it to a good baseline to start from for both maintenance and upgrades.
kawboy1962
Supporting Member III
Supporting Member III
Posts: 5
Joined: 12:59 pm Feb 01 2015
Country: United States
Location: Utah

Re: 2002 KDX220R Rebuild

Post by kawboy1962 »

Great Work, your Bike turned out beautiful.
User avatar
MoonStomper
Gold Member
Gold Member
Posts: 560
Joined: 02:05 pm Jun 02 2020
Country: USA
Location: Blacksburg, Virginia
Contact:

Re: 2002 KDX220R Rebuild

Post by MoonStomper »

Beautiful!!!!! Hope you have as much fun getting it dirty as you did getting it clean. Very inspired work you did there, especially fabbing your own custom tools throughout the project!
~^~^~^~^~^~^~^~^~^~^~^~^~^~^~^~^~^~^~^~
Let the good times ROLL!!!!!!!!!!!!!!!!
‘99 KDX 220 / '03 KDX 200 - @%@ '18 Trek Slash 8 @%@ ‘22 Rieju MR300 Racing

BLACKSBURG, VIRGINIA USA
User avatar
TwistedRoot
Gold Member
Gold Member
Posts: 323
Joined: 02:56 pm Oct 08 2017
Country: United States
Location: Florida, US

Re: 2002 KDX220R Rebuild

Post by TwistedRoot »

TheYakk220r wrote: 09:52 pm Apr 06 2021 Built a skidplate out of 1/2" poly board, jigsaw and propane torch. Welded up front and back brackets and installed countersunk hex bolts from the bottom. Added rubber 'gasket' along bottom of frame. Nice and smooth on the bottom and should be fun for jumping logs.
79.jpg
Thats a great job on the skidder! I think you should make some more and sell me one! Im not a big fan of the ricochet plate but it does what its meant to do.

VERY NICE YAKK!!
2002 KDX 200
2003 KDX 220
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: 2002 KDX220R Rebuild

Post by Slick_Nick »

Nice job! Let us know how you like the woods pipe on the 220. Last time I rode a 220 with one I was a little dissapointed. It's certainly meant for the 200.
'00 KDX 220R
TheYakk220r
Member
Posts: 51
Joined: 11:05 pm Jan 06 2021
Country: Colorado USA

Re: 2002 KDX220R Rebuild

Post by TheYakk220r »

Twisted, not sure I would make those to sell due to the hours involved but I will try and post the pattern and some other info coming up.

Nick, Thanks for the heads-up on the woods pipe. Might look into the desert pipe on the next upgrade session.

Thanks everyone for the encouragement and tips. Ran into some health issues last month so yet to get her out on the trail. Fingers crossed things settle down.
EmKwynn
Member
Posts: 7
Joined: 07:50 pm Oct 08 2019
Country: Canada

Re: 2002 KDX220R Rebuild

Post by EmKwynn »

What a great job! Plastics look amazing and I really dig the blacked out rims. Tres bien!
Post Reply