KDXRIDER.NET

I managed to break several things on my KDX today...and this was on the stand in the garage....
I had both wheels off to change tires and the bike was on the stand. I hadn't ridden it for a while so I thought I'd start it up for the hell of it.
I opened the choke and gave it a couple of kicks and it fired right up. Then my brain must have shut off because I forgot to close the choke and it started to rev up really high, I hit the kill switch but it wouldn't stop the engine. Then I decided to do what I usually do when it's revving for the moon and the plug is too hot for the kill switch to work...kick it in gear, drop the clutch and stall it. Only this time since I had the rear wheel removed when I dumped the clutch my chain wrapped around the front sprocket mashing my shift lever down and wedging between the sprocket and swingarm. Several things got broke but the things that concern me are: 1. the force of the chain being wedged between the sprocket and swingarm broke the engine case where the swingarm bolt goes through and 2. the shift lever was forced down way past it's normal position and I can't get it to move back up. This looks like a really expensive and/or time consuming mistake to have made. Can anyone tell me 1. can the engine case be welded and will it be strong enough and 2. what may be bent/broken in the gearbox and should it be easily replaced?

I sure do feel like an idiot for this one....

Any help would be great

Ouch.

Worthless without pics

Shoulda mad a video, you be rich

Couldn't even begin to tell you if the case could be welded without pics. And no telling what might have been damaged in the transmission just based on your description.

I'd start with splitting the cases and see what you are really dealing with. Then post some pictures so everyone can see what you've got.

You didn't say what engine you have, but there are several set of cases for E and H engines on eBay right now. It could be cheaper to just get a set of cases vs. getting yours welded up and possibly failing down the road.

Sorry, but:

Here are some pictures...it's not pretty.
This is a 93 KDX 250 by the way
The funny thing is that I had just got the shift lever tightened down on the shaft good after having a hell of a time keeping it tight for months, then this happens...just the time you'd hope it would spin on the shaft and avoid major damage...

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maybe you just spun the lever on the shaft?

Motor mount will hafta be welded or get a new case halve

I think if the lever spun on the shaft I'd be able to move it back up...It won't go.
Does anyone have any experience with having a case welded like this? I'd rather not open the motor up and buy a new case if welding can be done with good success.

If it was me I'd have it torn apart by now and found out what was going on in there

is the shifter jammed against the case/frame?

Where the chew marks in your shift lever there before this 'little' accident or the result of?

look at it this way........it could be worse! you could have busted out your clutch arm.

Not sure about the transmision. Put the wheel back on turn it and see. If all seems good start it up.

There are many ways to weld the case but unless you have a tig you would proably want to remove the engine for MIG or Oxy/acetyl. or use a product like HeatBlock

If you dont have a welding outfit try a aluminum brazing rod and using a MAPP gas or propane torch for heat. Or even better is a aluminum solder which requires very little heat but can be pricey. Soldering and brazing should both give you the strength you need. Check your local welders supply, Fastenal or even hardware store.

Thanks Chubby, that helps

I think its ruined and you should sell the whole mess to me for super cheap...as I need the cdi for my 93.....sorry i couldnt resist....kdx250's are pretty rare around where i live....

was looking up propane torches on harbor freight and came across this product that may be helpful.

http://www.harborfreight.com/pack-of-8- ... 44810.html

Duct tape....lol