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Re: HopFrog's 1980 KDX175 Build Log
Posted: 03:29 pm Jun 14 2021
by KDXGarage
I don't think it requires alignment. It just finds the hole through pressure, I suppose.
I am going to be bold and state that I do not think you will be riding this wonderful KDX175 through a lot of mudholes, so it would not require constant regreasing. :-)
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:49 am Jun 22 2021
by HopFrog175
Well, that hollow bolt idea for greasing the swingarm sure seems good. I stared at the parts on the bench for a good long while but could not see how to make it work with the KDX175 bearings - so I cleaned, lubed and put everything back together.
If a cheap swing comes up, I may get it and use it to try ideas on - for now, I will be re-greasing manually after any mud-hole incidents or other submersion - hopefully rare in the desert :-)
Re: HopFrog's 1980 KDX175 Build Log
Posted: 03:37 pm Jun 22 2021
by KDXGarage
The desert?! HA! Yeah, I think you will be just fine without the grease fittings. I have full confidence that you will regrease on a schedule, not let it go for too long.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 02:00 am Jul 08 2021
by KDXGarage
any thoughts to take the case half to have it TIG welded and sanded down?
Molly's 70 on here is a welding guy. See what he thinks.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 03:09 am Jul 08 2021
by Molly's 70
That might be a tough one to get the tig torch positioned right & still be able to see what your doing. I need more pictures of both sides.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 03:29 am Jul 08 2021
by KDXGarage
Re: HopFrog's 1980 KDX175 Build Log
Posted: 02:26 pm Jul 08 2021
by Molly's 70
OK, I went back to refresh my memory. I think I could get to it from the outsides of the cases. It would be nice to have closer-up pictures.
However, If those holes were plugged with JB Weld,(I think I read that) its pretty much a "no-go" unless every bit is removed. In fact, JB weld might be a good solution in this case.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 04:57 pm Jul 08 2021
by HopFrog175
any thoughts to take the case half to have it TIG welded and sanded down?
Thanks for the suggestion, this is a good idea. Here is a closeup before JB Weld.
1 of 3 holes
_click image to zoom_
- kdx175_00_errant_hole.jpg (339.6 KiB) Viewed 14272 times
- hf175w.jpg (5.94 KiB) Viewed 14272 times
Re: HopFrog's 1980 KDX175 Build Log
Posted: 07:29 am Aug 01 2021
by KDXGarage
Nice! Thanks for the follow up!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:05 pm Aug 06 2021
by Molly's 70
Good job on welding the holes in the case. Also, Good job on reworking welded area. It doesn't get any better!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 05:26 pm Aug 08 2021
by Slick_Nick
You will need new clutch basket bumpers to fix that slop. You can drill and tap the rivet holes for some flat head hex machine screws once you remove the stock rivets. I've done this on a few vintage Suzuki baskets with success. Use loctite and peen the screws once installed.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 12:30 am Aug 10 2021
by KDXGarage
"My initial thought was to stop by the local rivet place". I don't think I have ever heard that one. :-)
Keep up the good work!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:24 am Aug 10 2021
by Slick_Nick
I went down to my local rivet place when I did my flywheel rivets. They had hundreds of sizes in stock, likely ones that work for the clutch basket but I still elected to use screws for the last one I did, my old RM125. There's nothing wrong with screws if they're peened and loctite is used, will make replacing the bumpers in the future easier.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:20 am Aug 12 2021
by HopFrog175
I got the rivets out and looked inside of the clutch basket:
Original Clutch Basket Rubber Cushion Bumper Dampers
_click image to zoom_
- kdx175_01_clutch_disassembled.jpg (292.48 KiB) Viewed 13896 times
Now I see how this works. This is the first time I have had one apart and I have somehow never looked at pictures - I assumed it was solid.
And, I can see how the rivets just hold things together without transmitting any torque
The hard part looks to be sourcing the rubber dampers as I see about a half dozen Kawasaki versions exist. If anyone knows the right version, please let me know! I will do some calling around and see if someone can take some measurements too.
- hf175w.jpg (5.94 KiB) Viewed 13896 times
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:43 am Aug 12 2021
by Slick_Nick
You might have to do some measuring and poking around some various manufacturer catalogs since there likely isn't a listing for a bike as old as yours.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 12:01 am Aug 20 2021
by HopFrog175
Here is what I have found on the the rubber clutch dampers (cushions) for the KDX175:
KDX175 clutch damper (cushion)
_click image to zoom_
- kdx175_01_cushion.jpg (238.39 KiB) Viewed 13815 times
With help from HinsonRacing (thanks Robert!) it was determined that an exact match might no longer be available. The KX80/85 is pretty close but measures slightly larger. In particular, the inner "D" shaped hole might be too loose. Once I get the KX80 version in my hands, I will know for sure and, at that point, maybe I can shim somehow if it is too loose.
A better idea (or a closer replacement) would be welcome! Perhaps, given the correct rubber material, I could cut some on a laser cutter.
- hf175w.jpg (5.94 KiB) Viewed 13815 times