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Readers Rule! – 2005 Kawasaki KDX220 – Dirt Rider Magazine

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Wednesday, September 15, 2010

<strong>Staff Quotable</strong><br />n”Peterson has been known to have some pretty ‘What are you smoking?’ opinions when it comes to bike setup, but I was pleasantly surprised to see that he tested clean on Z-Man’s CRF. As much as I don’t wait to admit it, this was my favorite bike of the test. Well done, Cheech.” -Chris Denison/></a> <p class="wp-caption-text"><strong>Staff Quotable</strong><br />n”Peterson has been known to have some pretty ‘What are you smoking?’ opinions when it comes to bike setup, but I was pleasantly surprised to see that he tested clean on Z-Man’s CRF. As much as I don’t wait to admit it, this was my favorite bike of the test. Well done, Cheech.” -Chris Denison</p> </div> <p>You would die in a Dirt Rider production/editorial meeting. If you dodged the dullness bullet, then the smack talking, lame jokes and awkwardly inappropriate stories clogged with more tangents than a semester of trigonometry would have you searching for a noose and a stout ceiling joist. The irony in calling them production meetings is not lost on me, don’t worry.<br clear="all">But every once in a while my coworkers come up with a story that simply rules. And this time-it kills me to say it-Pete had a good one.The idea: Take four reader-submitted applications from the <a href="" rel="nofollow" onclick="javascript:window.open(www.dirtrider.com forums for a reality TV-style bike makeover. Try and keep a realistic $2,000 budget neighborhood, then, shoot them out against each other to discover which editor can actually fix a bike. Naturally, I’d be the judge since I’m the most levelheaded and sane one of the bunch. Or maybe I just can’t fix things… Our loyal readers are the winners. You, for taking what we’ve learned into your summer projects, and also our test-bike owners, for getting like-new, meticulously prepped, definitely improved and ultimately fresh rides! Plus, their bikes are famous now. So let’s get to it.
Staff Wrench
Pete Peterson
Reader: Sivan “Z-Man” Zuckerman
Bike: 2007 Honda CRF250R

Pete Says:
Z-Man is the ogre of Piru MX (www.pirumx.com), regularly circling at a Vet Novice pace. Z-Man’s bike had no real problems but was an example of what I like to call a “Jesse Ziegler,” something boring and with a few personality deficiencies that really grow annoying after a while. Z-Man’s Honda only needed an attitude adjustment, with the want list asking for a more forgiving suspension feel in the top of the fork stroke, a handling package that stuck better to inside ruts, a shifter that wasn’t mashed down into something that looked like it came off a 1979 Maico, graphics that didn’t remind you of a child’s worn-and-knee-patched jeans, and tires with knobs taller than its sidewall letters. wasn’t mashed down into something that looked like it came off a 1979 Maico, graphics that didn’t remind you of a child’s worn-and-knee-patched jeans, and tires with knobs taller than its sidewall letters.Pete’s Fixes:
The suspension went to RG3 for a full revalve and service, along with RG3′s shock link which is claimed to help calm the suspension, especially on corner exits where the Z-Bike will now really be hauling. A good chassis does no good if the bike can’t stick to the ground, so a set of Kenda Washougal Sticky tires went on front and back. Then an Acerbis X-Seat landed up top to make the cockpit an easier place to move around on. And right in the machine’s middle a Dubach Racing Development (DR.D) radiator lowering kit dropped the CG a bit. That was it to fix the handling. While I was at DR.D I had Z-Man’s muffler refurbished and repacked, a service the company offers to make your exhaust good as new inside and out. To round out the build Acerbis protection found its way over rotor and hands, Maxima guarded the internals with oil and the intake with a pre-oiled ProFilter air filter, Moose made the shifter reappear and Factory Effex got it looking like it just rolled out of a factory rig.Here Comes The Judge:
Pete’s date with this CRF was focused, fine-tuned and masterfully orchestrated. He didn’t waste big bucks up front and addressed this girl’s needs directly after putting in the time to get to know just what she needed. He ended up bringing a great-looking, sweet-handling and tight package to our shootout dance. The only thing he failed to do was make the winning move. While Z-Man’s ride truly corners like a dream with a healthy helping of plush comfort from seat to tires, it doesn’t do much in the get-up-and-go department. I’ve noticed firsthand the difference a top-end kit can make on a used 250F. And with well over 150 hours on this Honda 250F motor it was time for a new piston. The DR.D pipe repack was a smooth move. The suspension rebuild made the bike feel new and reciprocated that feeling to the rider. But a look in the cylinder would have been the ultimate way to seal the deal. But then again, Pete has never been that great at dating.Parts and Prices
RG3: www.rg3suspension.com
Fork and shock revalve with Gen 2 Smart Valve fork piston, fluids, seals and etc.: $788.37
Link cam and tie-arm with bearings: $439.95Dubach Racing: www.dubachracing.com
Radiator lowering kit: $49.99
Muffler repack (and refurbish) service: $59.95Acerbis: www.acerbis.com
X-Seat: $199.95
Spider Evolution front disc cover: $29.95
Spider Evolution front disc cover mount: $29.95
Vented Uniko hand guards: $38.95Factory Effex: www.factoryeffex.com
DX1 custom graphics: $189.95
DX1 Monster 2 custom number plate backgrounds: $54.95Kenda: www.kendausa.com
Washougal Sticky tiresMoose Racing: www.mooseracing.com
Aluminum shift lever: $39.95Maxima: www.maximausa.com
530MX engine oil (1 liter): $16.00
MTL trans/clutch fluid (1 liter): $8.00ProFilter: www.profilter.com
Ready-to-use air filter: $9.95Total Cost Of Fix-Up (Not Including Tires): $1,955.86
Total Man Hours: 4

<strong>Staff Quotable</strong><br />n”Peterson has been known to have some pretty ‘What are you smoking?’ opinions when it comes to bike setup, but I was pleasantly surprised to see that he tested clean on Z-Man’s CRF. As much as I don’t wait to admit it, this was my favorite bike of the test. Well done, Cheech.” -Chris Denison/></a> <p class="wp-caption-text"><strong>Staff Quotable</strong><br />n”Peterson has been known to have some pretty ‘What are you smoking?’ opinions when it comes to bike setup, but I was pleasantly surprised to see that he tested clean on Z-Man’s CRF. As much as I don’t wait to admit it, this was my favorite bike of the test. Well done, Cheech.” -Chris Denison</p> </div> <p><strong>Staff Wrench</strong><br /> Chris Denison<br /> Reader: Tanner Morgan<br /> Bike: 2005 Kawasaki KDX220</p> <p><strong>Chris Says:</strong><br /> Tanner Morgan isn’t your average 15-year-old. Weighing in at 190 pounds and standing 5 feet 6 inches tall, he’s built more like a varsity wrestler than a normal high school sophomore. Stature isn’t the only area where Tanner differs from his peers; instead of longing for a budget-busting factory four-stroke race bike, he’s perfectly happy with his five-year-old KDX220 trail machine. The young Texan labels himself as a “hard rider” who doesn’t race. Tanner rides the sandy, rock-strewn single-track terrain of West Texas, so ease of use and durability were a premium for this project. When asked to evaluate his motorcycle and provide some direction for the build, Tanner’s reply was simple: “I trust your judgment. Surprise me.”<strong>Chris’ Fixes:</strong><br /> When I got my hands on Tanner’s bike I discovered a microcosm of the average Dirt Rider reader’s bike: Ridden hard, slightly rough looking, well maintained. The KDX’s clutch and oil were in good shape, the top end looked great and there wasn’t any major crash damage. With hardly any major mechanical work to do, I could focus on preventative and performance issues.First, I sent the suspension to Race Tech, where they considerably beefed up the stock fork and shock to handle Tanner’s weight and riding preferences. I then turned my attention to the bike’s power, which Tanner had mentioned was a little mellow. A 49-tooth MSR rear sprocket (two bigger than existing) added some usability and low-speed torque. I matched that with a new Regina Z-Ring chain from MSR Hard Parts. Next, I installed a Moto Tassinari VForce3 Reed Valve System to wake up the throttle response and smooth the power delivery. Tanner had a nice FMF pipe/silencer combo and a solid skid plate on the bike already, so I took more of my $2,000 planned budget and put it toward a new MSR handlebar, grips and Pro Moto Billet hand guards. Then I adjusted all of the controls, took the slop out of the bike’s cables and fabricated an odometer mount to fit with the new bar/guard setup. I replaced the cracked and broken throttle housing and mudflap with stock parts, bolting on a fresh front fender while I was at it. Since I knew Tanner would be roosting across some harsh Texas terrain, I put on a set of Sedona MX887 tires. Although heavy, these suckers will last forever! Finally, I removed all of the old, crusty stickers from the plastic (counting logos from seven different gear companies in the process!) and installed a Factory Effex seat cover and graphics kit.In the end, I was able to improve the KDX in the areas that it needed without completely altering the bike’s character or going on a super-editor spending spree. Best of all, I know Tanner will appreciate the mods to his trusty steed and take care of this machine for years to come.<strong>Jesse’s Genius:</strong><br /> I don’t know a lot about KDXs. But I did meet Jeff Fredette at the ISDE in Greece. It’s safe to say I expected a lot out of Denison here. As a trail hound, the KDX pedigree is solid and Denison, surprisingly, didn’t ruin that with his A.D.D./freestyle/hyperactive build style. Yes, he was still working on it in the pits as we started to test. True, both he and his brother failed three times to put a tire on without pinching the tube. Also true, Chris surely wanted to chop fenders and carve grab holes out of the airbox for some Mulisha mayhem. But none of these things stopped him from building a bike that squirted around the dirt with maximum fun and comfort.Standout qualities of the bike were immense throttle control with solid traction, an incredibly quiet sound output and super-plush suspension that held up to my MX track abuse surprisingly well. I was confident enough to consecutively one-hand every jump at Milestone’s Vet track, ’nuff said. After riding this bike, I turned to my inner Fredette and he smiled at me with a neck full of ISDE gold medals while giving Denison and Tanner high-fives.<strong>Parts and Prices</strong><br /> Race Tech: <a href="" rel="nofollow" onclick="javascript:window.open(www.racetech.com
Gold valves, new fork springs, fork and shock rebuild with oil, parts and labor: $808.30Kawasaki: www.kawasaki.com
Front fender: $88.95
Throttle housing: $71.45
Mudflap: $24.60MSR Hard Parts: www.msrhp.com
Dominator handlebar: $49.95
Dominator grips: $7.95
Regina Z-Ring chain: $145.00
Steel rear sprocket: $119.95Sedona: www.sedonatires.com
MX887 IT tiresPro Moto Billet: www.promotobillet.com
FIT Version 3 hand guards: $124.95Factory Effex: www.factoryeffex.com
Evo 7 graphics: $69.95
All-Grip seat cover: $49.95Moto Tassinari: www.mototassinari.com
VForce3 Reed Valve System: $148.00Total Cost Of Fix-Up (Not Including Tires): $1,709.00
Total Man Hours: 10-12
<strong>Staff Quotable</strong><br />n”Peterson has been known to have some pretty ‘What are you smoking?’ opinions when it comes to bike setup, but I was pleasantly surprised to see that he tested clean on Z-Man’s CRF. As much as I don’t wait to admit it, this was my favorite bike of the test. Well done, Cheech.” -Chris Denison/></a> <p class="wp-caption-text"><strong>Staff Quotable</strong><br />n”Peterson has been known to have some pretty ‘What are you smoking?’ opinions when it comes to bike setup, but I was pleasantly surprised to see that he tested clean on Z-Man’s CRF. As much as I don’t wait to admit it, this was my favorite bike of the test. Well done, Cheech.” -Chris Denison</p> </div> <p><strong>Staff Wrench</strong><br /> Jimmy Lewis<br /> Reader: Jesse King<br /> Bike: 2008 Yamaha YZ250</p> <p><strong>Jimmy Says:</strong><br /> Jesse King was so stoked to be picked for this story he was speechless. Besides wanting to “race” us at Milestone Raceway, where he met us with his bike, he was pretty sure we would make his bike better. After calming him down and picking his brain a little, it was easy to see what it was going to take to get his YZ dialed. Jesse knows his motorcycle and had already made some wise modifications (a TM Designworks chain guide, Renthal sprockets, Magura hydraulic clutch, ProTaper top triple clamp, Enzo suspension revalve and a stiffer SDG seat). He also had some stuff that was not cooperating with each other. For instance: a pretty smashed Pro Circuit pipe and Shorty muffler don’t cooperate with Moto Tassinari VForce reeds in my opinion. But Jesse’s bike wasn’t a case of over-modification; it was more a matter of improper setup and noncompliant combos.<strong>Jimmy’s Fixes:</strong><br /> One thing Jesse didn’t do much of was maintenance. The suspension was sacked out and nowhere close to a perfect setting for his size or style, there was a drastic need for grease, and a little TLC would go a long way in things like swingarm linkage and steering head bearings. The piston was calling for a replacement, too. Since Jesse is taller his setup was very specific, and getting the bike to ride in a higher part of the stroke was important. And he needed his ride pimped on the outside for looks as well. I knew what to do: Refine and freshen so he’ll have a bike that is ready for at least another two years of abuse.<strong>The Other Jesse Speaks:</strong><br /> Jimmy and his Africanized Killer Bee-like social skills get a pretty bad rap. I get to hear all about it as he’s wandering around stealing sandwiches and beer from industry coolers. Surprisingly, Lewis held off on the blatant disregard for personal feelings when he met Jesse King and his bike. He must have seen the diamond in the rough here because before long Jimmy was giggling his way through this bike build in our shop. So, to the Jimmy-haters out there, this is going to hurt. Here comes a list of compliments.Jimmy took the herky-jerky power of Jesse’s YZ and built an MX and GP course killer. He smoothed the power with the FMF pipe/silencer combo and maxed the output with a new top end kit. Moto Tassinari replacement reeds cleaned up the throttle response, and a very trick Barnett full clutch assembly put the power to the ground. The bike was two-stroke wonderful with a long spread of instantly accessible power. The Enzo suspension service is one of the best values I’ve seen in moto mods and served as a great example to the company’s 100 percent satisfaction policy. Plus, these Galfer brake kits are amazing. If you want to mod your YZ right, Jimmy has just made you a shopping list.Usually, when Lewis builds a bike it’ll have super-ugly graphics, crooked numbers or a 100-gallon gas tank making it an easy target for mockery. But this time he even made Jesse’s bike look cool with the RidePG.com graphics and Acerbis plastic. I guess if I don’t have anything mean to say, I should just shut it. Because everyone knows Jimmy Lewis’ ego doesn’t need the praise.<strong>Parts and Prices</strong><br /> Moto Tassinari: <a href="" rel="nofollow" onclick="javascript:window.open(www.mototassinari.com
Replacement reeds: $60Enzo Racing: www.enzoracing.com
Suspension revalve: $290*
*Charged only the rebuild cost because of previous revalve and 100 percent satisfaction guaranteeAcerbis: www.acerbis.com
Plastic kit: $130Ride PG.com: www.ridepg.com
Graphic and number kit: $249FMF: www.fmfracing.com
Gnarly pipe and Powercore 2 muffler: $368Pirelli: www.pirellityre.com
Scorpion Mid-Soft tiresProTaper: www.protaper.com
CR Hi-bend bar and pillow grips: $103Barnett: www.barnettclutches.com
Clutch basket, pressure plate and Dirt Digger clutch: $625Galfer: www.galferusa.com
Wave rotors, steel braided lines and pads: $422Yamaha: www.yamaha-motor.com
Piston kit and gaskets, miscellaneous grommets: $168Total Cost Of Fix-Up (Not Including Tires): $2,415.00
Total Man Hours: 5 (including driving)
<strong>Staff Quotable</strong><br />n”Peterson has been known to have some pretty ‘What are you smoking?’ opinions when it comes to bike setup, but I was pleasantly surprised to see that he tested clean on Z-Man’s CRF. As much as I don’t wait to admit it, this was my favorite bike of the test. Well done, Cheech.” -Chris Denison/></a> <p class="wp-caption-text"><strong>Staff Quotable</strong><br />n”Peterson has been known to have some pretty ‘What are you smoking?’ opinions when it comes to bike setup, but I was pleasantly surprised to see that he tested clean on Z-Man’s CRF. As much as I don’t wait to admit it, this was my favorite bike of the test. Well done, Cheech.” -Chris Denison</p> </div> <p><strong>Staff Wrench</strong><br /> Karel Kramer<br /> Reader: Barry Jencson<br /> Bike: 2006 Kawasaki KX450F</p> <p><strong>Karel Says:</strong><br /> Known as Riding the Rockies on www.dirtrider.com’s forum pages, Barry Jencson is asking the impossible from one bike. He wants his 2006 KX450F to work on rocky Colorado trails and still handle the big landings of a motocross track. Basically, he added a spark arrestor and was simply getting beat to sleep on the trail where he does 80 percent of his riding to have power and jump suspension on reserve for the 20 percent of the time he spends at the track. He felt that ratio seemed way off, and he was definitely interested in having the bike work better on the trail. It isn’t possible to make it work perfectly in both places, but he was hoping for a better ratio than he had.<strong>Karel’s Fixes:</strong><br /> Barry and I aren’t that different in size or speed, so I just set up the bike the way I would like it for riding in Colorado but without ruining it for the track. The critical change was suspension. Race Tech freshened and modified the fork and shock, and I replaced nearly every chassis bearing with All Balls parts. The engine got a Vertex high-comp piston, Steahly flywheel weight and a quiet pipe from Leo Vince to tame the delivery. I demand smooth controls, and the Motion Pro cables and Revolver throttle setup with a Moose perch/clutch lever dialed the cockpit in perfectly. The bike needed to look and feel good, too, so Acerbis plastic, Attack Graphics and an SDG seat were slapped on. The entire brake system was freshened up including new Tusk rotors front and rear and, for reliability, a Primary Drive X-Ring chain and sprockets.With the Motion Pro throttle, Leo Vince pipe and Steahly weight the engine is now super smooth. Barry rides at altitude, so the Vertex high-compression piston really keeps the response solid and strong. The Clarke tank makes the bike look neat, enables long loops and made the riding position more comfortable for almost all of our test riders. I have to say I didn’t actually like the stock 2006 KX450F much, but I like this one. It has performance, comfort, protection and style. That’s all it needs.<strong>Jesse’ll Tell You What:</strong><br /> This bike reminded me of the 2009 Kawi 450 I raced at Loretta’s. I, too, looked to smooth the green beast’s delivery with quiet pipes and such; I worked to dial in the suspension and make it a more average-guy-friendly ride. And when people my speed and slower rode it they really liked it. What I didn’t do on my KX-F was pump up the brakes or put any effort into making the controls work perfectly. And my Kawi certainly wasn’t as versatile as this green monster in the end. The Clarke tank adds a surprising amount of flexibility to the ride and comfort as an added boost. These details, along with the reliability of fresh hard parts and the value of utilizing good used parts easily available on the eBay market make this KX-F an easy winner. And we haven’t even started to mention his near one-stop shopping at www.rockymountainmc.com.Karel’s bike was solid, smooth, comfortable, fast, bulletproof and good looking. A lot like most of us DR editors think we are. This took some money, but for certain it is the best example of the hidden potential inside a lot of our bikes.<strong>Parts and Prices</strong><br /> Vertex Pistons: <a href="" rel="nofollow" onclick="javascript:window.open(www.vertexpistons.com
High-compression piston kit: $196.66Cometic Gasket: www.cometic.com
Gasket kit: $54.99Steahly Off Road: www.steahlyoffroad.com
7-oz flywheel: $109.99Acerbis: www.acerbis.com
Replica plastic kit: $121.99
Rally Pro hand guards: $83.99Clarke Mfg.: www.clarkemfg.com
3.1-gal. fuel tank: $199.99All Balls: www.goallballs.com
Linkage bearing kit: $69.99
Swingarm bearing kit: $58.99
Chain rollers: $13.99 ea. (2)Primary Drive: www.rockymountainatvmc.com/dr
Steel sprocket kit with gold X-ring chain: $89.99Tusk: www.rockymountainatvmc.com/dr
Front rotor: $59.99
Rear rotor: $59.99
Carbon front brake pads: $13.99Boyesen Engineering: www.boyesen.com
Water pump cover and impeller: $164.99Ricochet Offroad: www.utahsportcycle.com
Skid plate: $87.95Motion Pro: www.motionpro.com
Revolver VR throttle kit: $139.99
Armor rim strip tape: $6.99
LiteLoc rim locks: $31.98
T2 clutch cable: $37.99Dunlop: www.dunloptire.com
Dunlop MX51 tiresAttack Graphics: www.rockymountainatvmc.com/dr
Slasher preprinted backgrounds: $44.99
Custom graphics: $75.95Moose Racing: www.mooseracing.com
Ultimate clutch system: $53.95Race Tech: www.racetech.com
Suspension mod/rebuild with Gold Valves: $702.15Maxima Lubricants: www.maximausa.com
Maxum4, quart: $11.99Renthal: www.renthal.com
971-08 7/8th bar, used: $70*Leo Vince: www.leovinceusa.com
X3 Enduro Sport titanium system, used: $800*Kawasaki: www.kawasaki.com
Cam chain: $45.11
Chain guide, used: $20 *
* Approximate based on used online marketTotal Cost Of Fix-Up (Not Including Tires): $3,442.56
Total Man Hours: 40Two motorcycle shipping companies deserve a big thank-you for bringing the two green bikes in from distant cities.
JC Motors
www.motorcycleshippers.com
800.730.3151Federal Motorcycle Transport
www.funtransport.com
800.747.4100 Ext. 217
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