2002 KDX220R Rebuild

[KDXGarage]

Why is it shiny? Is there some oil on it?

I think it has been replated in the past.

[TheYakk220r]

No oil on it. I haven't done any cleaning on the cylinder, this is how it looked after pulling it.

[tucker]

great write up so far keen to see how you get on.

[Tyl3r]

Looks great, nice progress! I like the soda blaster a lot too! If I had to guess, I would guess that was replated once before. The stock plating is so thin, I feel like you would be seeing wear in the vertical direction if that's what was still on it.

[TheYakk220r]

I think I'm going to change out the piston and run it this time around and then check it again in the fall/winter after the summer season, depending on how much I'm able to get out and ride. Might look at the cylinder and head mods at that time also. But for now, budget and time wise, I'm going to press on.

Thanks for the input all.

[KDXGarage]

I think it looks good. I would do the same.

Thanks again for buying the shock parts.

[TheYakk220r]

Thanks for having those available. Very helpful and good parts.

Got the main valve out after spraying some cleaner overnight. Cleaned up the carbon on the main valve and the exhaust valves. Light cleaning on the other parts.

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Doing some final cleanup on the lower case and the upper cylinder. Soda blast and fine wire brushing. Debating painting or just putting on some type of protectant or clear coat. Doesn't look half bad like this but still not sure until I get it back together. The side in the first picture looks newer so probably a replacement or refinished at some point.

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The original side is duller but cleaned up ok.

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Made some temp covers out of the removed plastic from the blaster cabinet lid to protect the cylinder while blasting. Stuffed some old undies in the bottom side.

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I noticed any little spec of grime sinks in pretty quick so it's going to need some sort of finish to keep it looking good. Very porous. I'm going to go back and remove the spring from the rear shock and coat the shock housing also while I'm at it.

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[KDXGarage]

"The side in the first picture looks newer so probably a replacement or refinished at some point."

Are you talking about the crankcase half?

The shock is hard anodized on 1989+. Obviously the cases, clutch cover, cylinder, cylinder head, etc. are not.

[TheYakk220r]

Yes, the crankcase half, right side.

[KDXGarage]

Someone may have pulled a switcharoo on the right half. Sometimes, they line up perfectly and sometimes they don't. That is why Kawasaki only sales them in pairs.

[TheYakk220r]

The alignment looks pretty close. I don't see any issues on the case.

KIPS...need some help here, please. My initial research is that the side port, behind the KIPS resonator cover, is open during idle/off and then closed during rev. Looking at Vossman's 2004 build that is how he was showing it also. Can someone confirm, or do I have it backwards.
Open or closed at idle? Thank you in advance.

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[KDXGarage]

chamber is closed off around 6,000 RPM and higher

1-8, 1-9 and 1-10 in my OEM service manual has a ton of info on it.

[TheYakk220r]

Thank you! I see that information now.
I was looking at the service manual sections 4-12 and 4-13 only. It mentions the notched teeth on the sub-valve but I'm not seeing those on the actual part.
Much appreciated.

[TheYakk220r]

Finished the KIPS and installed new piston. Went with the VForce3 on the reeds. Decided to go with the clear coat only on the motor rather than paint. I like the little imperfections in the finish and the color of the motor after cleaning it up. 3 coats clear engine enamel.

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Played around making a couple different fork tools. The slotted worked for getting the forks apart but made a drive using 1/2" pipe and a merchant coupling for installing. Not all that pretty, but worked well and was able to get the proper torque.

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Ended up replacing all of the fork seals and rebuilt the valves using the Race Tech kit.

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[TheYakk220r]

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.

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Forks, motor and swingarm installed.

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[KDXGarage]

Cool skid plate!

Good job on all of it.

[TheYakk220r]

Weather has been amazing and I'm enjoying putting it back together. Installed the freshly charged rear shock and suspension linkage. Everything greased up and to torque specs. Glued in the tank bumpers using Goop contact adhesive.

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Installed airbox, subframe, new rear fender, brakes, and wiring.

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Plumbing and handlebar items installed. Got some new lock-on grips that I'm impressed with. New clutch cable, lever, and repainted the mount.

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Plastics and wheels left to do. The parts pile is getting pretty small at this point. Waiting on a few more ordered items to arrive.

[harvesters01]

Whst paint did you use on the swingarm?

[Slick_Nick]

I used Dupli-Color engine enamel clear on my KDX engine once. Never again. It was yellow within a few hours.

[TheYakk220r]

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.