KDXRIDER.NET

Hey guys, i'm the new owner of a 1991 KDX 250. Traded a pinball machine for it, mostly because it reminded me of the big kits version of the 1980-something Kawasaki 80 I had as a kid.

Anyway, I was removing the clutch cable to replace it, and the casting which hold the clutch cable snapped - which is a big problem!

Anyone have a solution other than replacing the crankcase? Some sort of bracket or something? I have the piece which snapped off, but I'm guessing it can't be welded.

Mark

It can be welded. Just find someone who has experience welding aluminum.

I cant remember who made it and for what, but there used to be a little bracket that you could buy that would go on with a couple of the case bolts and it would come up to remount the cable when the casted mount broke. Something like that might work as well.

I just bought the left side crankcase on ebay for $50, so i'm thinking I might as well just change it.

Motor is still on the original top end from 20 years ago, so i'm thinking it might be time for a rebuild as well, and I have to do the clutch, and I don't think the coolant was ever changed.

I've never rebuilt a motor before - but I have a rough idea of how to do it.

I know I'm going to need a seal kit, and a top end kit, what else do I need?

Cases should be bought and sold in matched sets. You may get lucky, or you may have a problem getting the mating surfaces to match. If you're splitting it, you may as well replace ALL the bearings in the transmission, as well as the main bearings and seals. While it's open, you will want to inspect the rod bearings and see if the crank needs attention. You will need a flywheel puller to remove the flywheel. Also, some sort of case splitter to split the cases in half. With some scrap metal, a drill press or good hand drill, and a handful of bolts you can make one. You can also purchase a "universal" one pretty reasonably.

P.S. A service manual will be the best money spent!

Julien D wrote:Cases should be bought and sold in matched sets. You may get lucky, or you may have a problem getting the mating surfaces to match. If you're splitting it, you may as well replace ALL the bearings in the transmission, as well as the main bearings and seals. While it's open, you will want to inspect the rod bearings and see if the crank needs attention. You will need a flywheel puller to remove the flywheel. Also, some sort of case splitter to split the cases in half. With some scrap metal, a drill press or good hand drill, and a handful of bolts you can make one. You can also purchase a "universal" one pretty reasonably.

P.S. A service manual will be the best money spent!

+1

If you don't have local luck, ship it to me and I will weld it for free! I'm no hack you can check my website link.
Call it a 4th of july favor
-Matt

Thanks for the favor matt. Will try and get it welded locally, I think shipping will cost too much.

I just read the case splitting guide, I don't think I'm going to do that!

I have a mig, I could try welding it myself, but would need to pick up a spool gun.

Also know someone with a TIG.

What type of wire should it be welded with?

We use a 6061 blend and only TIG, I you MIG weld it you will not be happy.
-Matt