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Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:49 am Aug 30 2021
by KDXGarage
Man! Good job on working out a solution.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 05:30 am Sep 18 2021
by kaiser
hey mate great job!
i just pulled a kdx175 motor down mine has very thin shims between the crank and bearing, i couldnt see this in you photos, i had a look at parts diagram and unable to see these shims. just cuirous thanks!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:05 am Sep 19 2021
by KDXGarage
kaiser, can you post some pictures? That does not sound correct (as delivered when new)
Check my signature on how to post pics.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 05:34 am Sep 19 2021
by kaiser
Yea I thought it was odd as well. Here is a pic same on both sides.
- PXL_20210918_081823325.jpg (3.69 MiB) Viewed 16537 times
Thanks
Re: HopFrog's 1980 KDX175 Build Log
Posted: 03:29 am Sep 20 2021
by Molly's 70
I have seen washers on both sides of the connecting rod. Like thrust washers. Other Kawasaki 175's had them. I wonder?
Re: HopFrog's 1980 KDX175 Build Log
Posted: 11:42 pm Sep 20 2021
by kaiser
so i assembled without the shims, found i could push the crank side to side by about .25mm have decided to pull down my other kdx175 to look and no shims,
I have split the cases again and will put the shims in and see how it all goes.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 11:57 pm Sep 27 2021
by HopFrog175
Thanks for the update Kaiser. I will measure my crank side-play this weekend and feel better after hearing one engine had no shims!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 02:24 am Oct 01 2021
by HopFrog175
KDX175 Clutch Hub Rubber Cushion and Rivet Details
The clutch hub replacement cushion seems to be unavailable for the KDX175. The closest match that I could find is the KX80/85/100 '88-20. It is slightly larger than the KDX175 cushion and needs to be shimmed for a snug fit on the "D" post. The cushion also needs to be sliced slightly thinner to fit (see a few posts back for details).
The rivets are not listed by the parts suppliers and, presumably, are not available from Kawasaki. Working with a local rivet place, I used a close match to great success.
Part numbers and sources follow. See a few posts back for dis-assembly / assembly details and photos.
Quick list
Sep 30, 2021
OEM KDX175 cushions
- kdx175_01_cushion.jpg (66.52 KiB) Viewed 16022 times
Closest replacement KX80/85/100 '88-20 cushions
- kx80_02_cushion.jpg (93.05 KiB) Viewed 16022 times
Rivet diagram
- kdx175_03_rivet.jpg (105.99 KiB) Viewed 16022 times
Replacement rivet - allow 0.156" Clinch Allowance for total length of 0.621"
- kdx175_04_rivet.jpg (167.08 KiB) Viewed 16022 times
Rubber cushions (dampers)
Pro-X seems to be the manufacturer/importer of the rubber clutch cushions which are
available from several resellers.
Clutch cushion Manufacturer
Pro-X Part number Description
----------------- -----------------------------------------
17.CRS4198-6 ProX Clutch Rubber Set KX80/85/100 '88-20
https://www.pro-x.com/search/?search-brand=2&search-model=245&search-year=2003&search-submit=SHOW+RESULTS
- scroll down to "Clutch Cushions
Clutch cushion sources
SVS Powersports Part number Description Price
--------------------------- ---------------------------------- ------------------
115817 PROX CLUTCH RUBBER SET KX85 '01-18 $38 for a set of 6
https://www.svspowersports.com/
- clutch cushions may not be listed online - a call may be needed to order
-----
Parts Giant Part number Description Price
--------------------------- ---------------------------------- ------------------
383948 ProX Clutch Cushion Set KX85 '03 $36 for a set of 6
https://www.partsgiant.com/p383948-prox-clutch-cushion-set?f=126306
-----
Amazon Part number Description Price
--------------------------- ---------------------------------- ------------------
B07HF5498Y Pro-X 17.CRS4198-6 Clutch Rubbers $35 for a set of 6
https://www.amazon.com/s?k=B07HF5498Y&ref=nb_sb_noss
- SVS Powersports sold through Amazon
-----
Ebay is another possible source
--------------------------------------------
Rivets
Rivets are also unavailable from the usual motorcycle parts sources. The rivet place I went to had a close
match that was fine. If you contact other rivet houses, however, you may find a rivet with a closer match
of the diameter.
Rivet Manufacturer and Supplier
Hanson Rivet part Number Description
----------------------- ------------------------------------------------------------
Countersunk Head Steel rivet, countersunk head, 5/32" diameter, 0.621" length
https://www.hansonrivet.com/rivets/solid-rivets/commercial-solid-rivets/
- call to inquire
- ask nicely and a sample of 10 rivets cut to length may be forthcoming :-)
- the OEM rivet has a diameter of about 0.167"
- the new rivet has a diameter of about 0.156"
--------------------------------------------
Rubber Cushion Shim
Generic Supplier Description
----------------------- ----------------------------------------------------------------------
Vinyl tubing Black semi-rigid vinyl tubing, approx 0.590" OD, 0.075" wall thickness
- as described in the earlier post, heat the end of the tubing and fit it over the "D" shaped post.
- trim flush with the top of the post
- the new KX85 clutch cushion will now fit snugly
The end result is a bit stiffer as the new clutch cushions are slightly larger in OD - it takes a little bit of coaxing to assemble.
That's it
Re: HopFrog's 1980 KDX175 Build Log
Posted: 08:36 am Oct 01 2021
by Goofaroo
You’re making me feel like a slacker. lol
It’s not easy and very time consuming to document your work in such detail. You’re doing a very thorough job of bringing this 175 back to it’s original glory. Anyone following in your footsteps will certainly benefit from your hard work.
Keep up the good work and don’t think it is going unnoticed. I’m sure there are quite a few of us that will be following along until completion. Thanks for letting us tag along.
Re: HopFrog's 1980 KDX175 Build Log
Posted: 12:39 am Oct 02 2021
by HopFrog175
Thanks
Goofaroo, the people and posts on this site have been a great help. Hopefully I can add a little bit to it!
Re: HopFrog's 1980 KDX175 Build Log
Posted: 02:35 pm Oct 06 2021
by bazwalton
Hi HopFrog, Fantastic thread. Many thanks for the heads up on swinging arm sleeves. I am still riding and racing 175s weekly and was about to go down the making hardened steel sleeves as they are getting thin on the ground.
I have far too many 175s so awhile ago I looked about for replacements via bearing suppliers for the hard to find ones. The outer unitrack bearings are readily available from suppliers along with swinging arm bearings. The threaded rose joints are also easy to get. There isn't much point in me listing the suppliers as I'm in the UK.
The only one that is a bit of a dog to find at a reasonable cost is the centre of the uni arm. In the end I opened out the arm and used a different bearing. (I think there is still a post about it on my fb page, Classic Mann
https://www.facebook.com/Vintagekdx )
If you decide to lighten the bike with ally the 81 kx 125 swinging arm is the one to find. Also the unitrak arm is a lot of weight high up so switching to an ally version is all goodness.
I wish I had read you thread as you were posting about the grease nipples (UK term for zerks) as I looked into this a few years ago and realised the same thing, no clearance for the grease. ( I was literally mouthing at the monitor, don't drill it, don't drill it. )
On the upside the great thing about the 175s is that stripping them down and regreasing everything is so easy and fast that 'after every race' is a pleasure not a chore.
And finally, well done on the chronicling of each part of the rebuild in such detail. I have a whole tips and builds section on my page and I wish I had a pound (dollar) for every time I finish doing something, look over at the unsed camera on the side and think.. 'Bo***cks'. Hahaha.
Cheers
Baz
Re: HopFrog's 1980 KDX175 Build Log
Posted: 01:11 am Oct 18 2021
by HopFrog175
Hi Baz, thanks for writing in! It's good to hear you reached similar conclusions on suspension joints, grease nipples, etc. (Btw, I would welcome info on any additional suppliers, even in Europe -in fact, I got my Timken bearings from the UK and prices/shipping times were fine, under a week to get here).
Thanks for the swing arm tips, I figure I may go down that route once the shock gives out - I have no idea how long it will last.
I am looking through your facebook now, it is nice to find another treasure trove of kdx-ness!
Best,
Hopfrog175