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ok after another hour of screwing around, i think i *might* have it. The main exhaust port when it opens and closes, there's not a huge difference right?

Like 10% of the opening gets closed.. or am i doing something wrong?

I beleive you may have it right. did you line the groves on the side shafts up with the marks on the primary side valves?

TopperHarley wrote:I beleive you may have it right. did you line the groves on the side shafts up with the marks on the primary side valves?

Yeah i finally figured that out and finally was able to understand what they were talking about. I'm not a dumb guy, but this kind of stuff is not my forte'

cleoent,

I'm not a dumb guy, but this kind of stuff is not my forte'

hands on is the only way it will become your forte. I know some things can seem a bit intimidating and frustrating but were her to help. If you own a KDX, that, in itself, tells me that you are above average intelligence. Good so see yu diving into it. Just take your time and ask lots of questions.

ok fellas, i put in the new top end on the kdx220. (still waitin for exhaust valves on the 200).

Started up in one kick, i didn't ride it around because i've got my forks apart in anticipation of my springs coming...

Anyhoo, it was probably about 50 degrees out, and the bike idled fine but smoked the entire time it was on, even just at idle. This is normal, right? RIGHT?

depends on how much smoke and type of smoke. did you use a new head gasket and follow torque specs/sequence?

With a new topend the rings are not seated yet.

So Vince, you gonna give em the break in procedure I assume.

Ride it like you stole it after it's warmed up good!

Seems to work as good as any other method... trial by fire if you will....

I agree. Just don't rev it too too high or lug it too low. Keeping lots of pressure on the rings is the key. Gets them to bite and seat before you loose/smooth down your cross hatch on your cylinder walls as well as the sharp edge on your rings. I think the old method of heat cycling and letting it cool, blipping throttle etc. is more for the steel bore honed cylinder of yesterday. I have heard some people say to use some old school pre-mix at old school ratios because the new stuff is too slick and wont allow for a good ring seat. But I have not had any problems using new lubricants. Still manage to get a good ring seat.

now that I think about it, I did use dino when i put the top end in the 05. Used the stuff that i drained out the 02 when I took ownership of it. Another 05 engine i put top end in was broken in with Amsoil. It is the engine I am vurrently runnung in my 02. Runs great. plenty of power everywhere, no spoo either. Rings must have seated ok with it.

I still run Dino oil on breakin.. just 'cause I know it will breakdown and the rings will seat.

uh oh, i have to run a different kind of oil for break in??? doh! I'm using repsol 2st oil right now....

Is it full synthetic?

Run a non-synthetic oil for break in. After that, use something good, like AMSoil or Maxima.

Indawoods wrote:Is it full synthetic?

yep

Change it.

Ok, so here's what's done to my bike, air box lid, woods pipe and silencer, boysen dual stage reeds and of course the wiseco piston kit.

Living in CA i probably wont see anything higher then 2-3k above sea level. So here is the jetting i'm thinking about 40 pilot, 142 main, stock needle on 2nd clip from the top. These settings were recommended by the justkdx site for my mods.

thoughts? I can't damage anything with these settings right? Not too lean i hope...

Can tell you if it's reight or wrong, but I would try it and do a plug chop test.

a couple of follow up notes:

both bikes are put back together, the kdx200 feels very strong. Both start in ONE KICK! Awesome. Very awesome.

the kdx220 feels really good at full throttle, at mid throttle once it gets in the upper rpms it stutters, my guess is i need to move the needle clip down again to 3rd spot right? Is that a start? Or should i mess with the carb screws...??

Mid throttle, upper RPM's and with no load, it should make what is called a 4 stroking sound. That is good. If it's a clean sound, it's too lean. Ask CC. He's the one who helped me with that.