2003Kdxkid

Member
May 20, 2009
1
0
Hey guys,

Ive determined that my next bike will be a 2003 KDX 220R, I just have a few questions about what I should look for as to common problems.

Also how often will I need to rebuild the top end?

Thanks,

Geoff
 

glad2ride

Member
Jul 4, 2005
1,071
1
Have you read any on piston failures in the KDX220R? Many, including KDX expert Jeff Fredette at www.frpoffroad.com, suggest changing to an aftermarket piston, such as Wiseco.

Piston and ring replacement is based on how long and hard the engine is run. If you are the average guy and ride a fair amount, then rings every year and piston/rings every other year may be in order.
 

reepicheep

Member
Apr 3, 2009
670
2
I am rebuilding a badly beaten 95 KDX-200 I got "cheap" on Craigslist, and I can second those comments. When I pulled the top end "just in case", I found a cracked pistion skirt on the stock piston, worn through plating on the cylinder wall, and a raised "eyebrow" at the top of the piston stroke (again on the cylinder wall). I pulled apart the piston last night, and one of the rings had worn through half its thickness opposite the split.

The thing was probably only a few hours of running from breaking something, and putting shrapnel all through the motor.

The cylinder and head are in the mail today on the way to Eric Gorr, who is going to bore it out to a 225, plate it with Nickisil, port it, dismantle and clean the KIPS, and match the appropriate piston. $500... not cheap, but that's a lot of precision work, and everyone who has done the upgrade has been very happy with it.

Eric also mentioned that once you get the Nickisil coating, rings wear much slower, and the cylinder barely wears at all.

If you haven't bought yet, you might also think about getting a 200 instead of a 220 and doing the big bore. You end up in a better place, perhaps for about the same $$. The 200 has a bigger carb, and the big bore nickisil cylinder is far better then the stock tungsten deposition coating (which I think the 200 and the 220 both use).
 

ridejunky

Member
Dec 6, 2005
340
0
Piston change is easy insurance for a otherwise bullet proof, low maintenance motor, I ride quite a bit and do ring changes every other year. even at that they aren't bad. Good klotz synthetic oil helps keep it so. The most important thing is to change those stock springs up front as they are way to soft and throw a othewise good bike out of balance. Do a search for exhaustive coverage on spring changes.
 
Top Bottom