Reuniting with the KDX family, looking at a 01 KDX220

[denbsteph]

jb_dallas: That's a good point!

Maybe I should explain what I meant by " not taken care". The rollers on the chain are in good shape, the chain itself will "kink" and remain in that position as long as it is left there. I was hoping to get the chain off and soak it in kerosene for about thirty minutes then go to town on her. Clean thoroughly, wash in soapy warm water and give her the oil treatment.

I can get another riding season out the chain and sprockets, but the kinking has me concerned. I'm gonna look at the RM ATV site and see whats going on.

sr5bidder: I have doused that keeper and link with PB Blaster but the link is a bear. I'll give the link another run for its money tomorrow. Thanks for the info, I'll follow your method and see what happens.

sr5bidder:

What does this mean? "ohh I almost forgot when reinstalling the side plate I have a small c-clamp with a good sized divit in the spinny cup thingy and I position that divit on top off where the pin is and clamp down alternating sides till there is clearance for the clip to go on"

 

[denbsteph]

don't know what happened with the double post..........WTF!!!!

 

[jb_dallas]

The sproket/chain combos for your bike are $60 to $110...depending on what you buy. I think its money well spent... I would certainly pay a few bucks more (around $80) for a decent O ring chain combo. I bought a set for my WR and have no complaints.

 

[denbsteph]

Just got done looking at the Kits, The one I looked at was $75.00. I'm not a racer but from the reviews it holds up well for a weekend warrior like myself. "O" ring chain/ Steel sprocket set up, is what I looked at.

The Pipe, Silencer and Weisco shipped out Yesterday, the reeds will be here Friday

 

[sr5bidder]

best deal ever is the primary drive steel spockets, but be aware that your chain may be still good... look in the manual and measure the way it says, I would not soak into kerosene just yet, but get a BRUSH AND WORK ALL THE GUNK OFF (opps) first and then soak in your bucket of used motor oil and drip dry then run it a bit and see if its shot.
another good method I came up with is, with the chain off try to bend it against itself in an arch and if you can get anywhere close to a half circle replace it, it should look like the horizon as if you where on a ship in the ocean (i'm talking side flex here)

 

[denbsteph]

sr5bidder:

I believe that the chain is salvageable and the sprockets are in good shape. Your advice sounds good. I'm gonna get that link off and take care of the chain. The money I would of spent on the sprocket kit I'll use for a more reliable torque wrench.

I got home from work today and some goodies arrived. The Weisco kit, the Gnarly Desert Pipe and the Power Core II. I have to tell you that pipe is a thing of beauty, but for how long? Cant wait to get that thing muddied up, the Power Core II is extremely light, lighter than I thought it would be. This is going to make a world of difference in performance.

Oh ya, the Weisco Kit, I'm gonna double check the part number and make sure what I got is what I ordered. It appears that all things are coming together, plus I have a three day weekend coming up. Now I have to take my time and get things on correctly.

I'm going to add all the goodies on at once, it will probably be a pain in the arss to get her jetted correctly, but patience will prevail, now waiting for the reeds to arrive. Early Birthday presents are a great thing!! Now if the wife gets the Go Pro Helmet Hero, then it will truly be unbelievable.

 

[sr5bidder]

wow I have never had the cash to buy a new pipe I can only imagine how that looks, I was lucky that my kdx had the right pipe on it when I bought it.


I have to admit I could have bought a new pipe once a month a few years back but instead I would just go out and find a basket case to fix up every other month instead

 

[denbsteph]

I had put some cash aside several months ago and was waiting for another toy to purchase, (KDX and these goodies) I'm truly blessed to have a steady job that cannot be out sourced, overtime is abundant if you want it. The younger generation that has been hired in the last 5-6 years, don't want to show up for work, so us older heads take their slots.

Honestly, all the parts I got, Reeds, Pipe, Silencer, Weisco, Gasket set and to include the stuff from sr5bidder was a little over $500. I thought I came out ahead, bike included amounts to $1700. So far I have done ok, now it's time to put it all together and go riding!!

First things first, clean the cylinder. Next, get that damn chain clean, get a new keeper or better yet, get the Torque wrench first than start on the cylinder, chain and keeper. Either way it needs to be organized and not get into a hurry with it.

 

[sr5bidder]

nothing really to worry about...check the ring gap and put the rings on (my nerves get racked doing this still today) put the piston on the rod with NEW CIR-CLIPS, lube cylinder with 2t oil, squeez rings in and side cylinder on easy cheezy.

I would just borrow a torque wrench from auto zone or advanced.. pay for it/use it / return it ..that is how the tool loan program works here

 

[denbsteph]

sr5bidder: That's right, those two stores do have that program here as well, I forgot all about that. Check the ring gap? I'll have to look that one up in the manual. It's supposed to be beautiful here this weekend, hopefully I can work on it Friday afternoon and make some serious headway. We are starting to get hit with those storms that went thru your area yesterday. Some are supposed to be nasty.

 

[jb_dallas]

Personally, I would invest in a new chain. I know someone who took a chunk out of thier cases by not maintaining/replacing the chain...but, its your money.

 

[sr5bidder]

all I can say about that is clean and inspect that chain if its beyond the manual specs then you know what to do. otherwize ride on!! if it kinks up in place it may be a a chain with very little use, with tight o-rings that just needs a good clening and lube

 

[denbsteph]

Nothing wrong with a little extra cleaning, I have been doing that for several weeks now and I'm not about to stop. I want her right when I crank her up and blast down the road.

 

[denbsteph]

Going to pick up the reeds and master link this morning. This is the local guy that I mentioned earlier in the thread. I'll get his opinion for kicks and giggles concerning the chain. Tomorrow I'll start cleaning the cylinder then move forward from there.

I believe julien_d suggested soap and water. Should I avoid getting the KIPS valve wet? If so, how do I go about protecting it? I had to ask.

 

[sr5bidder]

well actually you should have the cylinder completely disassembled , take picture write down and lay out the parts (not too complex)

 

[denbsteph]

Take apart the KIPS? I just had to ask, back to reading again. F&&K!!!!!!!!!!!!!!!

 

[sr5bidder]

hey I thought you where going to get her buttoned up on friday??.

I might be headed to moto mountain here in a few if my buddy wasn't drunk talking last night!

 

[denbsteph]

Friday did not work out, yesterday was my b-day so I was relaxing, hung out with the family. I'm getting ready to go outside and get things going. I have everything now, reeds and the new master link & keeper. Gonna eat some leftovers, get my I-Pod fully charged and hit it with both feet on the ground!!!!! I'll update from time to time to let you know how it's going.

 

[denbsteph]

Getting motivated to some Tool and Perfect Circle "Judith" Imagine that, a 48 year old head banging to some Tool, A Perfect Circle, Rise Against, Black Label Society and of course Mr. George Carlin!!!! Time to go!!!!!

 

[sr5bidder]

just got ready for bed and scubbed off all the crud from moto mountain....I had a really decent ride today though I started out with a slid'n highside that threw me on my back... we will see how bad tomorrow how bad it was!! May be getting rid of the 03 kx, the kdx did everything I asked it to toaday
I hope you got past the nerves and got her done today

 

[denbsteph]

Holy Sh** Dave, listen to this, it sounds mad!!

Got her back together, no left over bolts, nuts or washers!

She started on the second kick first time. Second time, one small back fire,(if it was even that), then second kick. I have started her twice let her run for oh about 10 minutes each time. The first time just idle, slight throttle. Second time Idle, little more throttle, maybe 1/8 of the way. Everything is holding together, no leaks, no clunking sounds, hoping to get her out tomorrow down the road for a quick blast.

That FMF Pipe has an unreal sound to it, it sounds like someone beating on the inside of a steel trash can with a drum stick, it resonates from the expansion chamber and the sound, holy s**t, I can't explain it. Those who have this Gnarly Desert pipe know what I'm talking about, its f**king pissed. I want to take her down the street, but I know my neighbors and family will not appreciate it.

Has anyone had a piston c-clip decide to take flight? I did today, could not believe it, but I got EXTREMELY lucky and heard a "Ping" behind me, found it in about five minutes, got very lucky. I thought I was screwed. I have to get the new master link on tomorrow before I take flight, have to remember that.

Here are the items that were put on today:

Weisco Piston and Rings
Cometic Top end Gasket kit
Boyeson Power Reeds, 607
Uni-Filter, Dual stage filter
FMF Gnarly Desert Pipe
Power Core II Silencer
OEM Brass Muffler Donut
sr5bidders low boy seat, (no lowering links yet)

I think that is it, I was very anal about making sure things were on properly, that's why it took over 12 hrs!!. I hope I did not over think some things and over do anything, only time will tell I guess. The torque wrench is a funny thing, I really don't trust it. That's something I'll have to get used to..........maybe.

It's time to make room for the FZ1 and get her back in the garage. Any particulars I should look out for during break in? I'm going to assume, if she was gonna give me any issues, she would of done it during those initial start ups............right?? Paranoia is setting in, hopefully everything is good to go. Dennis

 

[julien_d]

With the forged piston, you always want to make sure it is completely warmed up before you beat on it. During break in, you want low RPM high load. Run it a gear high and keep a load on the engine. This will help the rings to seat properly. After that it's warm up and ride.

Congrats on the successful surgery!!

 

[reepicheep]

I don't think I have ever assembled a piston and NOT had at least one C-Clip take flight. My kids and neighbor kids are well accustomed to a $1 bounty to the finder whenever I launch one.

 

[denbsteph]

reepicheep: ROFLMFAO! Thank god I had one ear open, no music going or I would of never found it.

julien_d: Gotcha, low RPM, keep a load on her. How many times should I do this for? Once, twice, 1 hour or 2,. Like I said earlier, I'm pretty anal about things!! I'll try and load some pics using photo bucket, hopefully sometime today. Dennis

 

[denbsteph]

Anyone have a old stock filter cage hanging around? I'm in need of one, PM if you want to get rid of it. Dennis