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Re: HopFrog's 1980 KDX175 Build Log
Posted: 07:57 pm May 13 2021
by Goofaroo
HopFrog175 wrote: ↑12:48 am May 13 2021
Heh, I had to do something while waiting for the epoxy to harden
And your best idea was math?
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:41 am May 14 2021
by HopFrog175
Well, this seems to be the week of failures. I went to do another leakdown test after the JB Weld had hardened and discovered that my expandable plug had reached end of life.
Plug failure
_click image to zoom_
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Ok, no problem, found some bits and pieces for a substitute.
1/4" pipe thread
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Back in business, but no joy; the pressure drops from 5 psi at about 1 psi per 10 seconds
Looking for leaks
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I sprayed soapy water everywhere (seals, plugs, head, spark-plug, cylinder base, intake, case screws, case seam, hose/gauge connections), pumped up and removed the pump - the only bubbles are from the crank seals. Looking closely, I can see the leaks are on the outer edge, where the seal is metal on metal - probably should have used some RTV I guess - which I will now do by taking everything apart and putting in new seals with RTV! (mental note: do leakdown tests straight away before putting other stuff on)
At least my new socket-headed screws will ease the process
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Re: HopFrog's 1980 KDX175 Build Log
Posted: 07:21 am May 14 2021
by Goofaroo
Sorry to hear that. At least you’re getting very proficient at working on this engine. lol
Keep up the good work!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:00 am May 14 2021
by KDXGarage
Man. Sorry to hear it.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 12:32 pm May 14 2021
by HopFrog175
Thanks for the support! I even tried to find a way out with math - didn't help :-)
Re: HopFrog's 1980 KDX175 Build Log
Posted: 11:53 am May 19 2021
by KDXGarage
Please do not post pictures of a new carb, then say that you worked hard or smart to make an old one look like new. :-)
Are you sure it is the seals that are leaking? If you are taking it apart, try some kawabond 5 or similar on the halves.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:01 am May 25 2021
by KDXGarage
I think it may be more about air quantity, so use whatever oil quantity to get to the same oil level. The top of the oil level is the bottom of the air level / portion.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 11:38 pm Jun 06 2021
by KDXGarage
Look at what they did on the 1986 and 1987 KDX200.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:20 am Jun 07 2021
by Goofaroo
For each zerk you will also want a weep hole.
And what about the swingarm?
I put zerks in the swingarm and shock linkage on my KLR650. Kawasaki should have done it at the factory.
I have one zerk on the linkage that is facing downward and is vulnerable to damage by rocks and such. I pulled it out and keep a short bolt in there as a plug. I only put the zerk in there when I grease it.
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Re: HopFrog's 1980 KDX175 Build Log
Posted: 04:27 pm Jun 07 2021
by HopFrog175
Nice Zerks - thanks for the pics, I am inspired to continue! ( I am kicking myself for not putting them in when I first had everything apart ) The swingarm will definitely be included.
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Re: HopFrog's 1980 KDX175 Build Log
Posted: 05:39 pm Jun 07 2021
by Goofaroo
Yep. I was installing a new Cogent Dynamics shock and decided to rebuild the linkage and drill everything for zerks while I had it apart. It’s definitely worth the effort.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 04:29 am Jun 10 2021
by KDXGarage
The balls for 1986 - 1987 have slots with a hole, plus a bolt with a hole to allow the grease in.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:40 am Jun 10 2021
by Goofaroo
Sorry to hear that it didn’t work out.
I did a quick search on line for the ball joint boots that are part number 49006-1045 and came across some on EBay. Haven’t searched for the other ones but you might get lucky. I’m assuming your boots are pretty worn out by now.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:55 am Jun 13 2021
by KDXGarage
86 - 88 grease fittings are on the ends of the swingarm bolt with special sleeves to allow passage of grease
Re: HopFrog's 1980 KDX175 Build Log
Posted: 02:48 pm Jun 14 2021
by HopFrog175
86 - 88 grease fittings are on the ends of the swingarm bolt with special sleeves to allow passage of grease
Ah, the missing link of KDX grease joints, thanks memberlist.php?mode=viewprofile&u=6252KDXGarage
I am still stuck tho
In my case, I just do not see an easy path for the grease. The inner sleeves, spacer, shims and seals are in a stack which is compressed by the swingarm pivot bolt. For grease to get to the bearing from holes in the bolt, I would need to drill a hole in each sleeve and align each with the matching hole in the bolt. It seems like I would also need some way to index the holes and keep them lined up.
Zerk grease fittings may be in the future but, for now, I am just going to stay with periodic disassembly, cleaning and repacking.
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