Tight drive shaft fit on bearing? Attempting to re-assemble

[cstuckless]

I'm about to put my cases back together after a split. Just doing a dry run before I put the gasket material on, and it seems like the drive shaft is going to have a hard time clearing the bearing on the flywheel side of the case. Is that normal? Should I heat up that bearing to make it easier or just tap the case over it?

I recall it was slightly hard to work off, but nothing out of the ordinary... the inner portion of the bearing is not scored or anything, so I'm a bit baffled how it seems to be such a tight fit getting it started back on. Once the sealant goes back on I want to be able to work pretty swiftly, so I want to get a handle on this before I start.

I double checked the bearing part numbers, as I wasn't sure that the original owner might have substituted the wrong bearing. It's marked as a 6205, as per the parts diagram (part 601A): http://www.ronayers.com/oemparts/a/kaw/ ... /crankcase

Here's pics of the bearing, shaft, and the two coming together:






Colin

[cstuckless]

So I heated up the bearing a bit, tapped the case past the driveshaft with a rubber mallet, and using the Tusk crank tool got everything sealed up no problem. I tried sanding down the edges on the driveshaft a bit but I don't think that made any difference - the steel was too tough for my sandpaper to make any diff.

Colin

[cstuckless]

Now that I've got everything buttoned back up after my first ever case split, I have to install it back in the bike tonight and give it a kick. I feel like it's a 50/50 chance it either runs like a dream or blows up. Anyone else get that feeling after a split?? Should I drink beer before, during, or after??

Colin

[Gotanubike]

lol...film it and post results on youtube or vimeo

[Tioli]

Iv put a few motors togeather over the years and I think every one has some level of anxiety.

[cstuckless]

Problem with the kickstart not engaging/returning properly. Have to take the clutch case back off and check it out. Always one more step it seems :)

[Tedh98]

Iv put a few motors togeather over the years and I think every one has some level of anxiety.

The piston circlips are the ones that bother me most. I probably check each side 10 times to make sure they are fully seated. I would have a hard time letting it go that I didn't have it in all the way and it ruined the top (and possibly bottom) end.

[cstuckless]

Thanks Ted... I wasn't worrying about that before, but now I am.

[cstuckless]

Kickstart fixed, bike's running great! Going for a run this weekend to see how she rides. Colin