New 2002 KDX 220 Owner

[GREEN MANTIS]

Hi Everyone,

glad to join this community of kdx owners...
My Name is Felipe, 44 years old
Im from Caracas , Venezuela.
Sorry English is not my main Language..just in case I some times..
Been riding dirtbikes all my live..
Racing since 2002...B vet and then turned pro cuple of years ago.. now retired from racing...just trail riding for fun and to drain some stress .

Very happy to found this Website.. awesome info... Big Thanks to the Founder and Admins... Great Job Guys

Recently purchased a mint 2002 kdx 220 which was in a garage for many years without use... is in mint condition.
Surprised on how nice this bike handles compared to newer KTM I own.
Incredible handling in tight corners and trails... Awesome Bike considering shes a 2002.
Now Im beginning to Suit her to my riding style and preferences... Im ALL ears just in case anyone wants to give me advice on everything I should know from this KDX which is totally new to me.. Been only on KTM since 2001..those I know pretty well.

Any way , Glad to Join KDXRIDER.NET

Looking forward to learn from you guys ,

Cheers

[jjavaman]

You will want to check to see if it still has the original piston as they have been known to crack and break for no reason. Enjoy!

[GREEN MANTIS]

Hi jjavaman,

Well, Im pretty sure that its has the original Piston in it.
Thats almost hard to believe that the oem pistons break...how come Kawasaki thit not recall defective Pistons ?
Or is ust a fact for lucky owners , or unlucky ones ?

Any one here could give me a 100% assurance that the Pistons break for no reason on a 220 ?

Could be people not using enough oil on the premix ?

This bikes like to run rich right ?' 32 : 1 ?

[Tedh98]

Any one here could give me a 100% assurance that the Pistons break for no reason on a 220 ?

I don't think anyone is going to say 100% of all 220 pistons fail, but enough do to make it not worth the risk.

Spend $100 now or take the chance and possibly spend $100 + splitting the cases, replating the cylinder and maybe need to get a new head later.

If you search here you'll see that it happens enough to be concerned.

[offshoretitan]

Change the piston. It's a known fact that the 220 came from the factory with a failure prone piston. I've attached a picture of mine. I got to it about 12 hours of riding time after the purchase of a very low hour used bike. Very lucky the skirt didn't break and wreck my engine.

[canamfan]

Believe me the piston will break. Replace it now or pay more later. Welcome to the group. Good mods to do first, handlebar choice, aftermarket exhaust pipe. reeds, airbox mods, heavier fork springs , wider footpegs and get it jetted correctly.

[JFortner5]

Do it for sure. That is from my last 220. The one I just bought I never even started once I got it home, it was okay though. I don't know if it's hard to get parts or if you can import them easily but I just rebuilt my top end for about $140 USD.



Welcome to the forum.

[GREEN MANTIS]

wooww..
Then theres no easy way out guess..

ill have to do it..

Where I can get the piston , and what neccesary gaskets Ill need to get this done asap ?

[GREEN MANTIS]

Do it for sure. That is from my last 220. The one I just bought I never even started once I got it home, it was okay though. I don't know if it's hard to get parts or if you can import them easily but I just rebuilt my top end for about $140 USD.



Welcome to the forum.

WHERE DO YOU RECOMMEND ME GETTING THE NECCESARY PARTS FROM ??
THANKS

[Tedh98]

WHERE DO YOU RECOMMEND ME GETTING THE NECCESARY PARTS FROM ??
THANKS

Since you are outside of the US, I dont know where is the best place for you to order.

With that said, I use eBay or Amazon to get the best price on a Wiseco piston kit. Last time that was $80 for the piston and rings. I use ronayers.com for any OEM parts.

Keep in mind when you buy a piston kit it wont come with the small end bearing, so make sure you order that. Also make sure you dont end up with a cheap chinese bearing.

[JFortner5]

I ordered the piston and gaskets from Amazon. I think the piston was about $90 and the gaskets $30.

I ordered the wrist pin bearing from Rocky Mtn ATV/MC. It was Wiseco brand and about $15.

As far as what gaskets you need they are sold together in a set. Just search for top end gaskets and it should have everything you need. Last time I used Cometic and this time around I used a set of Wiseco gaskets, I couldn't tell much difference between the two.

I hope it's okay to post a link to an outside source but this is a very helpful how to-

http://www.thumpertalk.com/topic/657765 ... to-kdx200/


Sent from my iPhone using Tapatalk

[GREEN MANTIS]

Thats a Amazing link on how to do a top end on our KDX's....

Just plain perfect with pictures and all... also the explanation on how to remove or install that tricky KIPS set up ..OMG totally Blew me...

Congrats and thanks to point me on the right direction !!

[JFortner5]

You're welcome it helped me out a lot too. The first time I was a little intimidated by the KIPS but once you do it it's pretty easy.


Sent from my iPhone using Tapatalk

[Tyl3r]

OMG totally Blew me...

wtf, I clicked the link and it didn't blow me! hahaha

just playin! that is a good link!

[Tedh98]

I hope it's okay to post a link to an outside source but this is a very helpful how to-

http://www.thumpertalk.com/topic/657765 ... to-kdx200/

I remember that post from years ago, that is a good one.

The one thing that I would add that will make life easier is how to align the sub-valves and the exhaust rods. Instead of trial and erroring it, all you need to do is install the sub-valve (doesn't matter how it is positioned within the cylinder at this point) and then slide in the exhaust rod. Then all you have to do is pull up (it won't pull out of the cylinder) on the sub-valve and rotate it into alignment and then drop it back down. Like this:


Should take a couple of seconds to align it.