This KDX 220 has been sitting outside on my mate's drive for a very long time with no cover to protect it from the elements. Being on an island in the middle of the Irish Sea is not ideal weather conditions so this poor KDX has really suffered. The frame, forks and other metal parts were all very rusty and corroded and needed a lot of work to make them look good again. I sprayed the frame myself with cans that I bought from Ebay as the Ebay member was advertising the correct green for this model of KDX. I used silver car wheel paint that I bought from the local car accessory shop. Once I had finished the paint work and cleaning up the plastics etc I then started on the mechanical problems. The rear disc was completely worn out so I had to replace this. The rear brake calliper was seized up so I had to refurbish it with a new piston kit and brake pads. The front brake was OK but needed new pads. Both wheels had to have all new bearings fitted and I had the rear wheel rebuilt with new spokes. Juan Knight did the rear wheel re-build for me.
Now for the engine rebuild. I stripped the head and barrel off. The big end and main bearings were all fine. The chrome barrel was also in very good condition and I thought the piston was OK. However, on closer inspection I found the piston had a fine crack on the skirt (see picture) so I bought a new Wossner racing piston and rings (www.wossner-kolben.be). I finished building up the KDX and fitted new tyres and an after market new headlight.
Now it was time to start her up. Wow!! The KDX started third kick and was running lovely. I then came to start her again disaster - the kick start snapped in half (see picture) so I had to buy second hand one I found on Ebay. That sorted I could now road test the KDX. Well what a surprise, this KDX 220 is very quick. The new piston rings have made a big difference to the performance. The bike feels as quick as a motocross bike and when you wind back the throttle in 1st, 2nd and 3rd the bike wheelies without any help from me. In fact, I have to push down on the KDX to stop it from happening. The brakes are good and the suspension works very well and feels nice and plush. I have owned KDX 200s before but I have to say the KDX 220 is much quicker and that surprised me being only 20cc bigger.
A good website to check out for workshop manuals, parts manuals, hand books, and other Kawasaki books, pistons and clothing etc. www.classic-motorcycles.co.uk
