Maintenance & Technical > KDX (KX step child)

KDX 220 Project Bike

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Lunchbox:
Hi guys! So in my English class, we started a project called 20 time, which is based off a concept pioneered by Google where they give their employees 20% of their time at work for their own projects. Every week, we take a class period to work on these projects. Those of us that can't do their projects in class, such as myself, do the work outside of class and then do the documentation during class. That's where this forum comes in. I decided to rebuild the engine of a bike my dad (umberto on here) had. It's a 2001 KDX 220 engine in a 2003 KX 250 frame. It recently wore out from lots of use and poor maintenance by the previous owner,  so my das recommended I fix it to learn how to. It sat there for a while due to me being busy, and then this project came around. It was the perfect opportunity for me to do this. I did most of the work, my dad simply handed me tools and told me what to do when I didn't know. So here goes:

The bike as it sat:

Most of the goodies from it (suspension, rims, seat) were swapped with other bikes we have, so it's not as pretty as it used to be.

Part way through the process:

Fuel tank, shrouds, seat, pipe, silencer removed, subframe disconnected and set back.

With the engine removed:

Chain and radiators have also been removed

The engine:

Other than being a bit dirty, it's not bad from the outside.

Engine apart:

I had to pull the side off to get the KIPS linkage off. My dad had never taken a KDX engine apart, so it was a bit of a learning experience for him too. The cylinder is worn but not scratched. We've sent it off to Millenium Technologies to get it honed and recoated. It'll get a new piston and rings as well as the other important stuff like gaskets, clips, and bearings.

umberto:
Child labor is good, you should try it.   :-D

kmc14:
I have a Kdx 220 cylinder at millennium for replate, porting and head cut. I'm told the porting makes a big difference on the Kdx. I'll let you know the difference.

umberto:
Please keep me posted on the results. 

Danger4u2:
If you want to paint the frame I'll offer a free sand blast.

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