cant remove the shift drum

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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Two_stroke_brit
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cant remove the shift drum

Post by Two_stroke_brit »

Hi All, i am in the middle of replacing the crank seals ,managed to split the cases and went to remove the shift drum (removed the 2 6mm bolts.)
but there is the change drum holder on the other side of the case preventing it from pulling through.

i put a wrench on it but it just clicks round and round.
any help on getting it off
would be appreciated.
thanks mark
she might be older but still a fun ride.
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bufftester
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Re: cant remove the shift drum

Post by bufftester »

There is a bolt on the star gear (the change drum holder), IIRC it's a 12mm. That has to come out. It holds the change drum holder to the shift drum, sandwiching them to the bearing. It is clearly shown in the service manual and the cyclepedia manual
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Two_stroke_brit
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Re: cant remove the shift drum

Post by Two_stroke_brit »

yes but how do you stop the drum rotating when you try to undo the 12 mm bolt.
thanks mark
she might be older but still a fun ride.
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SS109
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Re: cant remove the shift drum

Post by SS109 »

I made a special tool for it. I just used a flat piece of steel and drilled three holes to go over the pins on one side. Then I ground a groove out of the side of it so the socket could get on the bolt. Worked perfectly. I can't remember what the diameter of the pins or the spacing are but it doesn't have to be perfect. Looked almost exactly like this...

DIY shift drum tool KDX.jpg
DIY shift drum tool KDX.jpg (21.62 KiB) Viewed 1304 times
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Slick_Nick
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Re: cant remove the shift drum

Post by Slick_Nick »

Two_stroke_brit wrote: 07:50 pm Jun 18 2021 yes but how do you stop the drum rotating when you try to undo the 12 mm bolt.
thanks mark
Undo the bolt before splitting the cases. The drum will be held in place by the forks.
'00 KDX 220R
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Two_stroke_brit
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Re: cant remove the shift drum

Post by Two_stroke_brit »

great advise on the tool ,i will make one up on my mill .
thanks mark
she might be older but still a fun ride.
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