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Now is probably your best time to replace that shift shaft. It'll likely stress other parts if you use it as is.
I don't know if it's a different part number for H and E series KDXs, but there are a couple of 95+ shift shafts on ebay right now for under $30.

"Good job, guys. "

They all look the same as mine


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I called the Kawasaki dealer. He said it's the same part e1 thru e6 or 89 to 94. It was 41$ out the door at the dealership for a brand new shaft. They were able to put it on another Kawasaki order that was being rushed before the weekend. So hopefully It will be in before saturday.


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I still got to figure out how I'm gonna straiten that shaft so I can remove it.


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So the Kawasaki dealership called me back and said that the part is discontinued. He called the the dealers in his network and none had one. Google and ebay is not coming up with anything so does anyone know of any motorcycle salvage yards?


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Tonight I think I'm going to attempt to straiten that shaft a little get it out of the housing.


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Be careful, as you might press against the inside of the card for accidental leverage

Before


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heating the shifter shaft



Nice cherry glow.

after


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looks almost perfectly flat now. I took a little 320 grit to it just to buff out the marks from the hammer and the groves from it being bent and rubbing. I'm pretty happy with how it came out.


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started wrapping the lighting coil.

And this is it all done



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A torch? Aw. You cheated. :-)

So im the middle of my reassembly. I wish i took more pictures especially of the transmission assembly. The cyclepedia manual is vague at times. Im hoping i get everything back and it works. Theres a lot of small pieces im not sure about. Alot of trial and error.


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anyone know where this is supposed to be


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I figured out where it goes.



Pressing the new bearings in. This is how it sits right now





Also my Rb carb came in











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Isn't the bottom end in the 89-06 KDX pretty much the same? That would make the 05+ shift shaft simply an updated PN.

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I don't know I've never owned a Kawasaki dirtbike before so it's a possibility I simply went off what the guy at the Kawasaki dealership told me he said that it would not fit. But I would be surprised if he just didn't know.


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Used to beable to look it up on Kawasaki's web site. I'm 90% sure the internal hard parts are the same from 89 and up. The main difference in the bottom end from E to H series is the inner clutch cover and parts associated with it (like the kips rod and water pump).

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Well good to know for the future. But meanwhile i think that shaft will work. Now back to the rebuild. I did have a few questions about wiring. Is the bike ac or dc. If i put a keyed switch on the wires coming from the stator would that be sufficient for a anti theft kinda thing so i can park it at work. Im gonna chain it down too but if im running into a store or something i wanna take the key so someone cant just hop on it and start it.


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