Kickstart idle gear

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
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HerptyDerpty
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Kickstart idle gear

Post by HerptyDerpty »

I’m currently rebuilding my 1989 kdx200 engine. I finally got around to removing the transmission shafts and gears and noticed the kickstart idle gear bushing is worn enough to let the gear move quite a bit. The shaft measures 14.96 mm and the I.d. Of the bush at 15.06mm so .1mm difference so .05mm clearance. Is that too much and has anyone replaced just the bushing? I don’t really feel like buying a new gear with bush for $70 when the bush is easily replaced. Has anyone replaced this bushing?
Garage:
1989 hybrid kx125 chassis w/ kdx200e engine
1978 gl1000
1984 vt500c
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SS109
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Re: Kickstart idle gear

Post by SS109 »

Never had to but it shouldn't be that bad to do so.
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bufftester
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Re: Kickstart idle gear

Post by bufftester »

I've not seen a source for the bushing, but if you're talking about the idler gear on the kickstart shaft that engages with the spur shaft (part number 59051-1309 here) IIWM I'd not worry too much about it if it hasn't been causing problems.
HerptyDerpty
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Re: Kickstart idle gear

Post by HerptyDerpty »

That is indeed the one. I bought a newer used one off ebay for around $20. Ill see how that one fits compared to the old one, maybe they just have that much radial play?
Garage:
1989 hybrid kx125 chassis w/ kdx200e engine
1978 gl1000
1984 vt500c
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bufftester
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Re: Kickstart idle gear

Post by bufftester »

I've not spec'd mine, but it has always felt a bit loose whenever I was in the motor.
HerptyDerpty
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Re: Kickstart idle gear

Post by HerptyDerpty »

The bushing in my newer gear measures at 15mm. Definitely a better fit with much less play.
Garage:
1989 hybrid kx125 chassis w/ kdx200e engine
1978 gl1000
1984 vt500c
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Re: Kickstart idle gear

Post by KDXGarage »

Is that the one that looks somewhat like swiss cheese on the inside??
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HerptyDerpty
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Posts: 25
Joined: 10:19 pm Jan 07 2019
Country: USA

Re: Kickstart idle gear

Post by HerptyDerpty »

Yeah that is the one. while searching for a replacement bushing i didn't come across any bushings that looked similar.
Garage:
1989 hybrid kx125 chassis w/ kdx200e engine
1978 gl1000
1984 vt500c
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