Opened Right Side Engine Cover - Need Help - Pics

[ihatefalling]

The goal here is to replace my sloppy shift shaft

When taking the right side engine cover off, I ran into a few issues. I'll break it into three questions:


QUESTION 1:

Right after I took the right cover off, I went to lay it down. When I laid it flat the exhaust valve advancer fell out. I didn't know it was in there. A small flat washer also fell out.



I believe that washer is part of the kick start assembly. I think it is part

92022C

http://www.motosport.com/dirtbike/oem-p ... -MECHANISM

Do ya'll agree ?



QUESTION 2:

When taking the clutch out, I inspected this center bearing:



The clutch pusher holder that the bearing is pressed in to spins freely in the larger aluminum housing but......when I squeezed on the inner sleeve of the bearing:



and tried to spin it, It felt like there were a thousand little ridges the bearing was rolling over. Make sense? It didn't spin smooth.....it spun with a bunch of small, soft "clicks" in it.

I wonder if the bearing is going out?




QUESTION 3 :

Inspected the clutch basket. It had grooves in it:








I've never had to file a basket before.
It it time too?
If so, do you just file the grooves till they are just smooth?

I've never had to replace a basket either.
From looking at the basket, there are gears riveted to the back of it.
If I have to buy a new basket, do the gears come already attached to the back?

Question 1, 2, 3

Thanks for your thoughts guys

[Fletch]

1. The EXACT same thing happened to me and I never found out where it came from... (But that engine went to the dump anyway)
2. That bearing should be smoooooooth.
3. How was the clutch working before the teardown? If it was fine then I'd leave the basket and not file it. Look for a replacement eventually but most of the ones i've seen on fleabay were worse than that. Let me know if you find an aftermarket one somewhere.

[turtle]

My thoughts on 2 & 3...

No bearing should operate like that. I'd replace it since you are in there.

My basket looked just like yours or maybe worse. I did a bunch of research, debated about buying a new one but I think you are right in that you have to move those gears to the new basket. That made me a little nervous. I called Fredette, and he told me he could sell me a basket but that if it was him, he'd file it. That was good enough for me, plus I am cheap. :). So I filed it. I felt like I took off a lot of material, but in the end it works perfectly and the clutch drag issues I was having pretty much went away. I used a file to get the ridges cleaned up then polished the edges with my dremel till they were completely smooth.

Hope this helps ya.

Edit to add, there are some pics of my clutch basket work here
http://rides.webshots.com/album/579440024KteteE?start=0

[gsa102]

Q 1 - looks like it, but need more pictures.

Q 2 - replace the bearing - it should be smooth with load in any direction.

Q 3 - Wiseco now makes a clutch basket for the H KDX. You didn't say what year yours was. You can file the basket or buy one. If you buy one, you just drill the rivets out and bolt the gear back on with the supplied bolts - easy.

[ihatefalling]

Thanks for the thoughts guys.
Bearing has been ordered along with new shift shaft, gaskets, etc..

Thanks for the basket pics.

I'll probably just file the basket since since it's never been done to this one, and I've never filed one personally.

Thanks for the heads up about the Wiseco basket.

[turtle]

Thanks for the heads up about the Wiseco basket.

Yeah thats a good find.

[gsa102]

Some riders on another site I follow convinced Wiseco to make them. I am going to buy one. I would hate to see it discontinued for lack of interest.

[turtle]

How much is it?

[ihatefalling]

Wiseco basket is $240

[ktm950se]

Great find!

[turtle]

Great find!

+1