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Re: HopFrog's 1980 KDX175 Build Log
Posted: 07:06 am Jan 28 2021
by KDXGarage
Thanks for taking us along with you. Good luck.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 12:31 am Jan 31 2021
by kick
Have fun bringing that bike back to life.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:45 am Feb 01 2021
by HopFrog175
Where to start? Seems like I was contemplating the rear suspension when I last turned a wrench on this project. Checking just now, yup, that slop I remember is still there.
I sprayed all of the bolts with Kroil (I hope Kroil is still in business, my can is pretty old) the other day as some looked pretty rusty.
Started by removing the shock and then wondered if it would still function so I pulled the spring off:
- HopFrog_kdx175_005_6.jpg (51.18 KiB) Viewed 21597 times
The shaft is pitted from rust
The shock on the KDX175 is crimped at the top leaving nothing to unscrew. Disassembly of the shock body might be possible but likely not worth the time and effort. Working up to 2000 grit made an improvement to the shaft, hopefully good enough - we will see. Once smooth, I was able to compress it - still has pressure!! After 40 years - amazing.
- HopFrog_kdx175_011.jpg (66.04 KiB) Viewed 21597 times
Still, it would be nice to have an update. But how? No direct replace shock is to be found as far as I can tell. That leaves a custom shock which would blow my budget so, for now, the old one will be given another chance. (If anyone knows of a close fit from another bike, please let me know!)
Cleaned up and greased the threads on the body and rings then reassembled.
- HopFrog_kdx175_008_9.png (1.02 MiB) Viewed 21597 times
- HopFrog_kdx175_010.jpg (120.61 KiB) Viewed 21597 times
Re: HopFrog's 1980 KDX175 Build Log
Posted: 03:27 am Feb 01 2021
by KDXGarage
Good job on the shock. It is not made to be a serviceable shock. Either buy a custom new one or roll the dice on another used one off eBay.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 03:06 am Feb 03 2021
by HopFrog175
With the shock out of the way, time for the rear suspension to come off, one rusty bolt at a time. Actually they were ok, spraying with Kroil must have helped. Rocker removed and on bench:
_click any image to zoom_
- hopfrog175_rear_suspension_11.png (1.4 MiB) Viewed 21580 times
The ol' Whipple-built press from Smith River, c.1960, pushing the old bearings out:
- hopfrog175_rear_suspension_02.jpg (220.92 KiB) Viewed 21580 times
And here are the new bearings Woot!! Woot!! I managed to snag these off ebay over the last year or so in anticipation of this project. Afaik, these are unique to the kdx175. Normally I would cruise by a bearing shop in Burbank to see if there was a match but when these came up, I took the lazy way out. Probably a few more $$ but no worries on fit. (I will post a parts list with sources in a later post.)
- hopfrog175_rear_suspension_03.png (1.12 MiB) Viewed 21580 times
Gotta get them started straight before pressing, much easier this way:
- hopfrog175_rear_suspension_44.jpg (305.32 KiB) Viewed 21580 times
Rocker arm cleaned up with new bearings in place (old bearings, on top, get saved, of course)
- hopfrog175_rear_suspension_06.jpg (488.06 KiB) Viewed 21580 times
I greased the new bearings but the ball-joints are pretty stiff. I guess this is good (no slop) and they will loosen up in use.
The links to the swing arm will be next.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 10:00 am Feb 03 2021
by KDXGarage
You must be a millionaire. Three new OEM bearings! Those things are NOT CHEAP when one can find them.
Good job on the shopping even more than the mechanical work. Seriously.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 12:18 am Feb 04 2021
by HopFrog175
Thanks! I shop slowly but to the point - "Millionaire", haha!
Actually, when I lack time to work on a project (too often), I try and prep for it. In this case, I had time to wait until the right parts appeared at a price I could afford. From ebay, the two outer bearings came at $32 each shipped and the center bearing at $60 shipped. Then they sat for a few years patiently waiting for their new home. I think I have a lot of what I need but will find out what's missing as I go.
- hf175w.jpg (5.94 KiB) Viewed 21567 times
Re: HopFrog's 1980 KDX175 Build Log
Posted: 02:35 am Feb 04 2021
by KDXGarage
You are welcome. I have done a bit of "for the future" shopping as well, especially a decade ago before eBay sellers jacked the prices of NOS items through the roof.
Keep up the great work!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:14 am Feb 04 2021
by Goofaroo
The first thing that I bought on EBay was a clutch basket for my 85 model XR350R. That was over 20 years ago and I still have it on hand if I ever need it. lol
I’m tagging along on your build. It’s nice to see one of the early models brought back to life.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:39 am Feb 05 2021
by HopFrog175
Re: HopFrog's 1980 KDX175 Build Log
Posted: 09:19 am Feb 05 2021
by KDXGarage
Man. Looking good! Again, good job.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:01 am Feb 07 2021
by KDXGarage
The weight of that steel swingarm must be up there. :-) I bet it is sturdy, though.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 02:59 am Feb 10 2021
by HopFrog175
KDX175 suspension rebuild details
Having just rebuilt the rear suspension on my 1980 KDX175, a write up is called for First, many thanks to mlyle11's thread: KDX 175 suspension rebuild from a few years back, I am basically just adding some details to that very helpful writeup. I will start with a quick list and then follow up with all the gory details.
Quick list
Feb 9, 2021
59266-1001 - 2 required - Rocker arm ball joint
source - ebay - $30-$60 availability and price vary
source - CMSNL.com - $127 each
https://www.cmsnl.com/kawasaki-kdx175-a1-kdx175-1980-usa-canada_model15171/joint-ball-suspension_592661001/
source - PartNumberPros.com - $69 each
https://partnumberpros.com/products/kawasaki-59266-1001-suspension-ball-joint-kx-kdx?_pos=2&_sid=130a03c74&_ss=r
92028-1087 - 1 required - Rocker arm center bushing/sleeve bearing
source - ebay - $30-$60 (availability/price vary)
source - CMSNL.com - $120 each
https://www.cmsnl.com/kawasaki-kdx175-a1-kdx175-1980-usa-canada_model15171/bushing-suspension_920281087/
59266-1002 - 2 required - Suspension up-right rod-end
source - ebay - $30-$60 (availability/price vary)
source - CMSNL.com - $102 each
https://www.cmsnl.com/kawasaki-kdx175-a1-kdx175-1980-usa-canada_model15171/joint-ball-suspension_592661002/
source - Bearing Supply #1 - $12 each
https://www.qualitybearingsonline.com/pos12ecl-qbl-left-hand-maintenance-free-type-with-male-thread
source - Bearing Supply #2 - $13 each
https://www.vxb.com/POS12-Male-Rod-End-12mm-Right-Hand-Bearing-p/kit12360.htm
92046-1031 - 2 required - Swing arm needle bearing
source - ebay - $20 (availability/price vary) search for 20x27x30mm needle bearing
source - CMSNL.com - $23 each (availability varies)
https://www.cmsnl.com/kawasaki-kdx175-a1-kdx175-1980-usa-canada_model15171/bearing-hmk2030-needl_920461031/
source - Bearing Supply #1 - $10 each
https://www.vxb.com/TA2030-Needle-Roller-Bearing-20x27x30-Metric-p/kit21216.htm
42036-1031 - 2 required - Swing arm, sleeve for needle bearing
source - ebay - $30 (availability/price vary)
source - CMSNL.com - $37 each (availability varies)
https://www.cmsnl.com/kawasaki-kdx175-a1-kdx175-1980-usa-canada_model15171/sleeve-swing-arm_420361031/
Alternative sleeve - requires cutting length to size of 52mm
42036-1031 - 2 required - Rocker arm bushing/sleeve for 1999-2003 kx125, kx250
source - ebay - $20-30 (availability/price vary)
source - CMSNL.com - $11 each (availability varies)
https://www.cmsnl.com/kawasaki-kx125-l1-1999-usa-canada_model11928/sleeve_420361357/
That's it! More or less expense and hassle depending on your time factor. Naturally, use best practices when buying from un-vetted sources and evaluate the suitability of each part before use.
Details
Next, more details on the KDX175 rear suspension joints than you ever wanted to know :-) Measurements were made directly off of the parts by me and are not exact. Also, I measured in inches and converted to mm, sometimes putting down the number I already knew to be correct, e.g. I knew that the swing arm sleeve has a 20mm OD even though the measured inches converted to 19.9mm. For Bearing suppliers, sources, I looked at a fair number but many more exist. If possible, visit one in your neighborhood with your old bearing; they know a lot more than I do and may be able to get the parts. The Rocker arm ball joints and the center bushing/sleeve are just plain unusual, though, with the 27.5mm outer diameter. I did not find any matches but if all else fails, a bearing supplier may be able to get one with a 28mm OD and you could have the rocker bored to match. Same with the center bushing/sleeve. For the rod-ends, variations exist with zerk fittings and some kind of sealing or cover. Different styles of rubber rod-end covers are available on ebay too and it seems like at least one style might work although they all look bulkier than the originals. As for wheel bearings, that are commonly available so I did not include them in the list.
Rocker arm ball joint
Id x od x width (ball width) ===> 14mm x 27.5mm x 17mm
_click to zoom images_
- zzzkdx175_spherical_bearing_diagram.jpg (638.54 KiB) Viewed 21465 times
Rocker arm center bushing/sleeve bearing
Id x od x width (sleeve width) ===> 14mm x 27.5mm x 17mm
- zzzkdx175_bushing_diagram.jpg (682.78 KiB) Viewed 21465 times
Suspension up-right rod-end
Id x thread length x width (ball width) ===> 12mm x 36mm x 16mm (12mm threads)
- zzzkdx175_rod-end_diagram.jpg (1.1 MiB) Viewed 21465 times
Swing arm needle bearing
Swing arm, sleeve for needle bearing
Id x od x width (bearing width) ===> 20mm x 27mm x 30mm
Id x od x width (sleeve width) ===> 15mm x 20mm x 52mm
- zzzkdx175_needle_bearing_diagram.jpg (2.53 MiB) Viewed 21465 times
Alternative - REQUIRES CUTTING LENGTH TO 52mm
Rocker arm bushing/sleeve for 1999-2003 kx125, kx250
Id x od x width (sleeve width) ===> 15mm x 20mm x 53.8mm
- zzzkdx175_needle_bearing_sleeve_alternate.jpg (1.66 MiB) Viewed 21465 times
That's it - Whew!!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:52 pm Feb 10 2021
by KDXGarage
a tidal wave of awesomeness has hit the KDX175 beach
What an excellent post! Thank you for sharing the information with the world!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 12:28 am Feb 11 2021
by KDXGarage
As before, excellent work. I can even read the words more easily. Thanks for the "large print" edition.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 05:00 pm Feb 11 2021
by bufftester
Nice write up and great luck on finding those bearings, they are unobtanium for the most part.