I put Factory effects Graphics on my 2000 KDX 220 that had the original plastic. The kit fit perfectly on my radiator plastic. Sounds like there is a problem with your after market plastic.
I purchased 2002 replica side graphics and they fit proper but the prt of the kdx part was cut off,checked with another supplier, it was the same, I was dissapointed in them and will never buy them again, live and learn, maybe they share the same building as fmf :laugh:
I recently put on new UFO plastic, and didn't have much problem. The shroud holes don't match quite as clean as factory, but I didn't have to cut or drill.
And I put One Industries graphics, and they fit just fine. It looked like a new bike! :-)
The top hole on the left shroud is about 3/8" from where it should be. I don't know how to make it fit without expanding the current hole, and then the fit will be sloppy.
Oh well, let me go find my drill and Exacto knife...