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Newb - 03' KDX 200 rebuild help

Posted: 11:03 am Jun 23 2020
by sangle333
I know there's tons of threads talking about rebuilding the top end etc. but, I'm a total newb on 2T.

Why an I rebuilding? Well just bought it earlier this year and with your help I fixed the leaking pipe from the engine and found a stock air box. Overall the bike runs good although the engine is loud like the piston is slapping. The guy I bought it from raced for 2 years on it. He said he looked at the piston and it looked fine but, after 2 years of beating on it I'm guessing I should replace the piston in hopes the slapping goes away.

I've read Wiseco is preferred. Do I buy the kit or just the piston?

Is there a step by step video or thread on how to rebuild the top end?
- Do I need to take the engine off the frame to do this?
- I read about the 'left' threaded bolts. Check
- And to support the shaft when removing the nut. What do you use to support it? Anything that will fit?

Thanks in advance!

Re: Newb - 03' KDX 200 rebuild help

Posted: 11:23 am Jun 23 2020
by KDXGarage
kit and small end bearing

piston
rings
two circlips
pin
small end bearing
gasket kit
fresh coolant

do not need to take engine out

Left Hand threaded bolt and nut is the KIPS advance shaft

Yes. DO SUPPORT it when turning. flat wrench, adjustable wrench, etc.

Re: Newb - 03' KDX 200 rebuild help

Posted: 02:02 pm Jun 23 2020
by sangle333
KDXGarage wrote: 11:23 am Jun 23 2020 kit and small end bearing

piston
rings
two circlips
pin
small end bearing
gasket kit
fresh coolant

do not need to take engine out

Left Hand threaded bolt and nut is the KIPS advance shaft

Yes. DO SUPPORT it when turning. flat wrench, adjustable wrench, etc.
https://www.powersportsdiscount.com/product/42124
Thanks Garage - Is the above link what I should purchase?

Re: Newb - 03' KDX 200 rebuild help

Posted: 02:56 pm Jun 23 2020
by Molly's 70
That's the right kit. Sometimes it's just a generic picture to fit all.

Re: Newb - 03' KDX 200 rebuild help

Posted: 04:38 pm Jun 23 2020
by sangle333
Molly's 70 wrote: 02:56 pm Jun 23 2020 That's the right kit. Sometimes it's just a generic picture to fit all.
Seems like a decent deal too. Purchased!

Re: Newb - 03' KDX 200 rebuild help

Posted: 08:47 pm Jun 23 2020
by doakley
sangle333 wrote: 02:02 pm Jun 23 2020
KDXGarage wrote: 11:23 am Jun 23 2020 kit and small end bearing

piston
rings
two circlips
pin
small end bearing
gasket kit
fresh coolant

do not need to take engine out

Left Hand threaded bolt and nut is the KIPS advance shaft

Yes. DO SUPPORT it when turning. flat wrench, adjustable wrench, etc.
https://www.powersportsdiscount.com/product/42124
Thanks Garage - Is the above link what I should purchase?
Service Manual!

Re: Newb - 03' KDX 200 rebuild help

Posted: 11:24 pm Jun 23 2020
by KDXGarage
I agree!
manuals.JPG
manuals.JPG (73.57 KiB) Viewed 2342 times

Re: Newb - 03' KDX 200 rebuild help

Posted: 08:32 am Jun 24 2020
by sangle333
Yes, yes...finally bought one because of this. Ugh! Thanks for you help!!

Re: Newb - 03' KDX 200 rebuild help

Posted: 10:44 am Jun 24 2020
by KDXGarage
The beatings will continue until morale improves.

:mrgreen:

Re: Newb - 03' KDX 200 rebuild help

Posted: 10:48 am Jun 24 2020
by pumpguy
KDXGarage wrote: 10:44 am Jun 24 2020 The beatings will continue until morale improves.

:mrgreen:
I LIKE THAT! :grin: