I have a question concerning kdx's. I own a 2000 KDX 220 and the case is ****ed beyond repair. I also own a 95' KDX 200 motor. My question is if anyone knows how compatiable these cases are, They look like the same. What i was thinking of doing is taking all my 220 parts and jug and putting it in the 200 case. Has anyone ever done this? or should i just break down and buy a new oem case for $400.
Thanks Gentleman

 

I've just checked the schematics on Bikebandit.com and the 95 200 and 2000 220 have all the same fittings (bearings, seals, nuts, bolts fittings etc) so I'l say 99% that the cases are a direct swap. Evolution of the breed, 200cc became 220cc in the space of 5 years.

 

Thanks westoz, i think i'm gonna start tearing it apart to do the swap. If for some reason it dosen't work then i'll eat it and buy a new case. Thanks man

 

Well boys, i did the swap and everything seemed to work fine. the bike started right up and ran good. The only problem i am having is the clutch dosen't work. The cable seems to have to much slack in it and it. It seems like the clutch rod is not engaging. Does anyone know what can be going on here? Thanks

 

Sounds like you need to adjust your cable

 

I did that, i took the cable almost all the way out and it seems like there is clutch but its not engaging. I'm not sure of whats going on.

 

Is the case mounting point for the clutch cable in the same spot in relation the pull arm?
Maybe there is a slight difference between the 200 and 220 and now the cable is the wrong length?
Did you use the 200 or 220 bits that are attached to the case?

 

I used the same side cover so the relation should be in the same spot, however i put my 220 clutches in the 200 case. I'm wondering if the 200 clutches have to go back in. But i checked schmatics and part numbers for 95 200 and 2000 220 and there the same. I'll see what happens this weekend.

 

May sound strange but start the bike in neutral, pull the clutch, pull in the brake, and downshift into first gear. The clutch on my '01 KDX doesn't engage all of the time unless I follow that procedure. I even had a new clutch installed and still it's the same...

The clutch won't engage many times if the engine is off and you pull the clutch in and try to push the bike. But if you pull the clutch in and kick start it, everything seems to work fine. I have no idea why but from the research I've done there are some other KDX owners out there with the same issue. The only time it seems not to engage is when the bike is off, in gear, and you try pushing the bike. Even that's intermittant. Give it a go. Good luck.

Mike

 

You guys are probably gonna want to Bitch slap me now. I found the problem!! I didn't have the washer between the basket and alum plate. After i researched the schamatics i seen the washer. Luckly i had an old set of kdx 200 clutches, i took it off them and it worked excellent. Thanks again for the help boys. I'll probably have some more KDX questions in the future.