KDXRIDER.NET

Slick_Nick wrote: 10:08 am Nov 02 2022 Yep that thing works a treat! You can also use it with a bearing separator to pull those crank bearings back off the crank for re installation.

Ready for reassembly

Bearing separater worked very well.
Thank you!

Damn seal lip folded over on me AGAIN. Just barely but I gotta get it perfect.

I greased the inner lip of seal and crank pretty heavily and still happened.

Not sure what to do at this point haha idk what I'm doing wrong

Crank is out. Going to try again soon.


Alright.....got crank in & that one seal/bearing is done & perfect.

Now we'll see bout the other seal when joining these cases!

Awesome!

Cases are back together and second seal looks excellent!

Hell yea!!!

Thanks everyone for the help!! I appreciate it very much.

Will never forget this experience.

You've learned a lot and now know you can rebuild any dirt bike engine!

Clutch install question.....

Can't seem to get the pressure plate all the way down to the bottom. I don't remember having that gap up top when I took the clutch off....

Seems like it just needs to go down one more steel plate and get flush....?
What's going on here?

Try to assemble it like he does in the video. You’ll see at one point he talks about it not seating all the way down.

Probably the last row of teeth on the inner basket isn’t lined up with the bottom metal plate. It can be tricky.

Tried following the method in that youtube video....unfortunately no success. If I do it that way, no gap up front but have a gap in the back towards engine.

Only way clutch pack is seating all the way down is without the inner washer pictured below. Not sure why. Got me stumped.

If I put the washer in there, it fills up most of that round area for the bottom of inner hub to drop in but I believe without that washer I'd just be bolting the two clutch hubs together....

Do you have the washer that goes behind the basket installed?

SS109 wrote: 05:16 am Nov 08 2022 Do you have the washer that goes behind the basket installed?

This. Also, I can already see that the bottom plate isn’t lined up with the fingers of the rest of the metal plates. They all need to slot into the inner hub.

I'm with SlickNick, that last one isn't in line with the rest. A little off topic but what kind of basket and hub is that? Mine has only 4 springs

DonnyV wrote: 04:25 pm Nov 08 2022 I'm with SlickNick, that last one isn't in line with the rest. A little off topic but what kind of basket and hub is that? Mine has only 4 springs

E series bike

Thanks again to all who helped with that!
I think I have the clutch sorted out.

Now onto the top end....(I should probably update the thread title to "full rebuild")

I can feel a spot with my finger nail in the cylinder and I'd like to send it out to get worked on.

I believe best option would be to have it re-plated?

Someone local to me suggested sending it to "LA Sleeve" in California?
Anyone have any opinions on that?

Just send it to millenium or powerseal.

L A Sleeve does what their name implies, they do sleeves. If you want a re-plate, send it to a plating specialist as Slick_Nick advises.

I sent mine to Millenium and was very pleased with the results.

I sent mine to Millenium after FRP porting. Came back looking new.

Thanks guys!!

I think I'll go with Millennium for the plating.

Any other options besides FRP for the porting?
Not opposed to them, just curious!

KC93 wrote: 10:45 pm Nov 09 2022 Thanks guys!!

I think I'll go with Millennium for the plating.

Any other options besides FRP for the porting?
Not opposed to them, just curious!

Millennium does porting as well. If you're really going to do all that, it's a really good time to make sure the head squish is done as well.

SS109 wrote: 10:51 pm Nov 09 2022

KC93 wrote: 10:45 pm Nov 09 2022 Thanks guys!!

I think I'll go with Millennium for the plating.

Any other options besides FRP for the porting?
Not opposed to them, just curious!

Millennium does porting as well. If you're really going to do all that, it's a really good time to make sure the head squish is done as well.

So for taking care of the head squish...just also send the dome to Millenium?.....along with the cylinder, new piston, new rings, and I'm going to have them do porting & install my new steel power valves from the guy in England (already got those and they look really nice....bike had the usual LH valve sheared). Just saw on Millenium's website they can take care of that as well.

Gonna be expensive Good thing I got the bike for basically nothin' as a work trade & just wanted to learn about dirt bikes, especially 2 strokes. Glad I at least got something "good" to eventually fix up & keep

This website is great & I appreciate everyone's help very much!!