KDXRIDER.NET

bought a 2002 kdx220 in need of a lot of work early december 2016.
been at least 20 years since i've had a 2 stroke.

i'm about to split the cases. bought RM case splitter & crank puller.
my 1st time splitting cases.

cylinder was repaired by millenium technologies & looks great.

Welcome to the forums.

Congratulations on your KDX.

Welcome

Welcome. Make sure that the piston is not OEM while it's all apart. Tons of info here to help you out. There is nothing on these bikes that can't be worked on with just a modest set of shop tools and a small handful of special tools. Good luck and show the pics!

finally uploaded some pictures. most people like pictures...



as it sits, or has been sitting for some time now. and yes, the pink helmet is mine
chassis pretty much ready to go. all bearings replaced and/or greased as needed.



most of it on the shelve. just waiting to get the crank back & i can start my 1st attempt at re-assembling a bottom end.



the crank. i checked run out. wasn't too bad. still decided to send it out. they will remove the bearing, which saves me about $60 for the tool to remove it.
the other bearing was still in the case. i removed it with some threaded rod.
i pressed crank out on a press at work.



new tusk impact rear rim with buchanan spokes. oem had a crack on rim. missing & frozen spokes too. yippee!



piece of what i'm assuming was a piece of a previous piston wedged in con rod.



some debris found on bearing after splitting cases.



more debris & it doesn't look like seal was put in right.

that's where i'm at now. want to try to get crank seals & bearings in today perhaps.
thanks for letting me share, and hope it's not too long or too many pictures.

Did the stock piston break?

Thanks for the pictures.

Jason wrote:Did the stock piston break?

Thanks for the pictures.

If I had to guess, I'd say yes. Looks to me like a piston came apart at some point and previous owner put in a wiseco while ignoring damaged cylinder.

Bike ran fine during test ride. Motor didn't make any odd noises that I noticed.

Wow, another awesome previous owner