GEAR CHANGE SHAFT

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
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cptk3rk
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GEAR CHANGE SHAFT

Post by cptk3rk »

91 KDX 200
Problem is gear change shaft
someone who owned it before me had end of the shaft all welded up and the teeth are all worn out, has a hole drilled through it and he ran a bolt through it, and on top of that the shaft is bent badly, and it doesn't return to center position

cant find a new shaft.

theres a guy who offered to turn a new shaft on his lathe

so my question is what sort of pullers do i need to get it out? non of my automotive pullers fit.

looking on rockey mountain ATV
Tusk Crankcase SplitterTusk Crankcase Splitter
Part #1177390001
Mfg. #17-8668

Tusk Crank Puller/Installer ToolTusk Crank Puller/Installer Tool
Part #1177380002
Mfg. #17-8667

The C-clip adaptor (part # 1329270001) is required for cranks that use a C-clip to hold the primary gear on (common on many Kawasaki models).

not sure if this stuff works on the older E series because when I select Year make and model non of these tools are on the list, so im not sure if they work
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Re: GEAR CHANGE SHAFT

Post by KDXGarage »

Welcome to kdxrider.net. Thanks for signing up AND participating.

Sorry that a "previous owner" was not a "Mr. GoodWrench"!

I'd hold off on a used one from eBay. Here's one that I think is worn or WORN OUT (look at the two grooves). https://www.ebay.com/itm/1993-Kawasaki- ... Swy2NfWqUX

The cases are NOT split to remove and install the gear shift shaft. The inner / outer clutch covers come off (as a pair, no need to separate them). I can't remember if the clutch has to come off or not.

This Kawasaki 13161-1170 LEVER-COMP-CHANGE SHAFT Not Available fits the following models and components:

Kawasaki Motorcycle 1992 KDX200 - KDX200-E4 Gear Change Mechanism

Kawasaki Motorcycle 1991 KDX200 - KDX200-E3 Gear Change Mechanism

Kawasaki Motorcycle 1990 KDX200 - KDX200-E2 Gear Change Mechanism

Kawasaki Motorcycle 1989 KDX200 - KDX200-E1 Gear Change Mechanism

Kawasaki Motorcycle 1994 KDX200 - KDX200-E6 Gear Change Mechanism

Kawasaki Motorcycle 1993 KDX200 - KDX200-E5 Gear Change Mechanism
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Re: GEAR CHANGE SHAFT

Post by Molly's 70 »

IIRC the clutch basket needs to be removed. The shaft will slide out. Sounds like your going to have to cut it.
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Re: GEAR CHANGE SHAFT

Post by cptk3rk »

cool, hey thank you so much KDXgarage I ordered that asap, it wasn't showing up on my search results for some reason, funny how two different computers can pull different results

what tools i need to split the case, need to clean the lower end, the teeth on the valves were all disintegrated rounded off, would like to split the case clean it out add new bearings in the lower end anyways.

( I have new kipps Steel Vavles already and new head for it im sending for replate )

are the ones i linked from rocky ATV right tools?
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Re: GEAR CHANGE SHAFT

Post by KDXGarage »

I am not sure on the tools. I know a few people on here have mentioned them in the past.
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Re: GEAR CHANGE SHAFT

Post by cptk3rk »

https://ibb.co/3BhKfpK
Image

for anyone that wants to chime in, tools necessary for splitting the case on E-series motors, or any other links, names or serial numbers of the tool you use would be appreciated, thanks
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Re: GEAR CHANGE SHAFT

Post by KDXGarage »

The splitter looks good, as well as the clutch holding tool. I am not sure on the puller, if it works with an "E" model.
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Re: GEAR CHANGE SHAFT

Post by cptk3rk »

okay ill try it out
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Re: GEAR CHANGE SHAFT

Post by cptk3rk »

The front left fork is damaged worse then i thought when i pulled the boot off has large dent

i see a pair of 89 forks on ebay I can get that have no rust or dents, but the guy said he thinks the 89's are little different from the 91's and to make sure before i order

I have the outer fork tubes all powder coated up already so will the 89 inner tubes fit on 91 outer tubes?
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Re: GEAR CHANGE SHAFT

Post by KDXGarage »

89 - 92 inner and outer tubes are the exact same part numbers across those years.

This Kawasaki 44013-1300 PIPE-FORK INNER Not Available fits the following models and components:

Kawasaki Motorcycle 1990 KDX200 - KDX200-E2 FRONT FORK

Kawasaki Motorcycle 1989 KDX200 - KDX200-E1 FRONT FORK

Kawasaki Motorcycle 1991 KDX200 - KDX200-E3 FRONT FORK

Kawasaki Motorcycle 1992 KDX200 - KDX200-E4 Front Fork (KDX200-E4)
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Re: GEAR CHANGE SHAFT

Post by KDXGarage »

Basically:

the inner tubes are 1989 - 1992 KDX200

the outer tubes are 1989 - 1992 KDX200

Drive on down from Wisconsin, I'll give you a tube from my '90 ... or '91 ... or '92 ... or from my spare set. :rolleyes:
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Re: GEAR CHANGE SHAFT

Post by cptk3rk »

waiting to see if this guy takes my offer on Ebay
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Re: GEAR CHANGE SHAFT

Post by KDXGarage »

OK, cool.
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Re: GEAR CHANGE SHAFT

Post by cptk3rk »

it would cost the same in gas, round trip then what id pay to order it, my truck is a gas hog
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Re: GEAR CHANGE SHAFT

Post by cptk3rk »

found a whole complete lower end engine for 150, lucked out, and a swing arm with linkage, very nice condition :grin:
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Re: GEAR CHANGE SHAFT

Post by KDXGarage »

That's pretty good! These bikes may have been plentiful, but quality spares are not cheap any more.
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Re: GEAR CHANGE SHAFT

Post by cptk3rk »

did they used to make FMF Gnarly desert pipes years ago for E-series? I know Fatty is the only current option, been keeping my eyes out on Ebays for the Desert pipe.

or maybe a muffler shop could bend a 95+ to fit?
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Re: GEAR CHANGE SHAFT

Post by KDXGarage »

I don't think they ever made a Gnarly pipe for 1989 - 1994. They make two versions for 1995+ KDX. Gnarly is one gauge of steel thicker than Fatty.

I doubt it would be worth the trouble to make a 1995+ fit. The pipe runs lower at the end vs. higher style on the 1989 - 1994. This is called "low boy" pipe 30 years ago. :-)
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